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
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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 machine
Reliable machine
Energy efficient
machine
Safer 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
TWh
16%
Haushalte
609 TWh
25%
Industrie
729 TWh
30%
Verkehr
714 TWh
29%
Energy Consumption
in Germany 2011
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Safer machine
Energy efficient
machine
ErP Directive
Energy 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 Directive
The Goals Behind ErP Directive
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Safer machine
Energy efficient
machine

ErP Directive
Implementation Guidelines / Regulations
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ErP Directive
Impact 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
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machine

Motor Regulations
• Content, Scope
• IE3 suitability of switching and protection devices

70
75
80
85
90
95
100
1 10 100 1000
Motorefficiency(%)
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 Regulations
Efficiency Classes on Motors
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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 Regulations
Efficiency
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lower cost machine
Safer machine
Energy efficient
machine

Motor Regulations
Technical Consequences
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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 Regulations
Example: Modifying Motor Starters
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Eaton Motor starters are the most simple,
ready to use and reliable way to run IE3 motors
Motor Regulations
Motor Starter “IE3 Ready”
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Energy efficient
machine

Pumps and Fan Regulations
• Content
• Valve system versus speed control system

Content
• 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
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Source: ZVEI
Comparison 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
Performance(kW)
Flow (%)
Throttle Valve
Speed Control
Comparison Energy Consumption Valve System vs. Speed Control System
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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 Starter
Options for Starting Motors
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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
The Starter with Variable Speed
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Safer machine
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
Applications
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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
Used Everywhere in the World
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lower cost machine
Safer machine
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
Perfect for Panel Building
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lower cost machine
Safer machine
Energy efficient
machine

Reliable 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
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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
If necessary…
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lower cost machine
Safer machine
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.
lower cost machine
Reliable machine
Energy efficient
machine
Safer machine

Further Information
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Energy efficient
machine
Safer machine
„Motor Protection for the
IE3 revolution “
„Successful implementation
of the ErP Directive“
For more information, you can visit : www.eaton.eu/IE3

The ErP Directive and its impact on switchgear

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