Our energy-saving motors –making a profit for you

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If you are going to purchase a new motor or overhaul a used one you should first do your arithmetic.

One thing is crystal clear: energy costs represent a high proportion of the overall operating costs.

If the operating costs can be reduced, profitability can be increased and your production becomes

more environmentally friendly.

Our new energy-saving motors do precisely that – they reduce operating costs. And they prove just

how cost-effective motors can be, as they require even less energy for the same output – day in, day

out. And, we can clearly demonstrate how cost-effective they are.

An offer you can’t refuseWe are one of the few motor suppli-ers in the world today who can offermotors which are perfectly harmo-nized with the highest efficiencyclasses:

• High-efficiency energy-saving motorsin the highest EC efficiency classEFF1 (high efficiency)

• Improved-efficiency energy-savingmotors in the EC efficiency classEFF2 (improved efficiency)

• Energy-saving in compliance withEPACT (US Energy Policy Act of1992) for 60-Hz operation

It goes without saying that all of ourmotors are in compliance with theapplicable standards and are thereforefully compatible.They fulfill all of theimportant specifications – worldwide.

In the black – but still greenEnergy costs represent over 97% ofthe life cycle costs of a motor – initialpurchase price and installation costsare just 3%. For our latest generationof energy-saving motors, we havefocussed our attention on efficiency.Thanks to optimal material utilizationand innovative technology, we havebeen able to reduce the heat lossesof our motors by up to 45% (!). Theoperating costs are significantlyreduced – and the somewhat higherinitial purchase price is paid back inthe shortest time.

Move up to THE energy-saving classEFF1 energy-saving motors have anextremely fast payback time, espe-cially in continuous operation. Here isjust one example: for a 4-pole 5.5-kWenergy-saving motor in continuousoperation, by changing from EFF2 toEFF1 – with energy costs at 0.10 europer kilowatt-hour – you can obtain anenergy saving of 219.00 euro perannum.This means that the higherprice of an energy-saving motoris already paid back after approx.2900 operating hours – i.e. after4 months of continuous operation.That has to be good for profitability.

The life cycle cost analysis clearlyshows that users have the highestcost-saving potential by using energy-saving motors.

1.5 15 110 Rated output [kW]

Life cycle costs [%]

100

50

0

2.30.9

96.8

1.10.2

98.7

0.90.1

99.0

Purchase price

Installationand main-tenancecosts

Energy-costs

Motorlifetimein years12 15 20

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Economical but nonetheless powerful

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The energy-saving potential of electric drive systems is enormous. According to ZVEI in Germany

alone, it amounts to approximately 20 TWh – this corresponds to the power output of eight fossil

fuel power stations. When it comes to the environment, this represents 11 million tons less of

carbon dioxide emissions.

Economically, this means energy cost savings of about 1.5 billion euro per year. What are the

saving potentials for you? What do you have to consider? When does it make sense to move up

to efficiency class EFF1? Our checklist will give you answers to all of these questions.

Full energy reserves:the energy-check listHere are some interesting consider-ations for a noticeable reduction inyour energy costs:

• When purchasing new motors, takeinto account the energy costs andthe initial purchase price.

• Above 2000 operating hours peryear, EFF1 energy-saving motorsare always more economical. Foractuators or shorter operating timeson the other hand, the EFF2 energy-saving motor is the bestsolution.

• Siemens’ energy-saving programoffers the ideal platform to make aselection – whether the EFF1 orEFF2 energy-saving motor.

• The energy costs are perceptiblyreduced when old motors are re-placed by energy-saving motors.

• Especially when it comes to repair,it pays to calculate whether newenergy-saving motors are moreeconomical. Both from the perspec-tive of the high repair costs, as wellas the fact that in general a motorrewind reduces the efficiency byseveral percentage points. Further-more, motors can be almost 100%recycled.

• Always check whether it makessense to use AC drive inverters tocontrol the speed so that the com-plete energy-saving potential canbe utilized.

Good arguments for Siemens energy-saving motors

With Siemens energy-saving motors you have a whole range of benefits:

• Complete range of energy-saving motors in compliance with EC/CEMEP and EPACT

• Motor selection is extremely simple as a result of efficiency classifi-cations (EFF1/EFF2)

• 1LA9 and 1LG6 motors fulfill both EFF1 and EPACT efficiency ratings

• Operating costs are reduced due to higher efficiency

• EFF1 and EPACT motors have higher motor and lubricant lifetimes due to the lower motor operating temperatures

• Less CO2 emissions to reduce environmental stressing

• High overload reserves in continuous operation (SF 1.15 for 1LA9/1LG6)

• All motors can be used with inverters up to 500 V

• Integral part of Totally Integrated Automation (T.I.A.) via the AC drive inverter and PROFIBUS-DP®

250

200

150

100

50

0

Operating hours

En

erg

y co

st s

avin

gs

in e

uro

s

0

En

erg

y co

sts

in e

uro

/kW

h

0.10

0.08

0.05

1000 2000 3000 4000 5000 6000 7000 8000 9000

Payback time for an assumed extramotor price of 73 euro for a 5.5-kWEFF1 energy-saving motor with0.1 euro/kWh: 2900 h

Energy savings of 219euro per annum for 8760 hand 0.10 euro/kWh

2900 3600 5800

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Are you fit for the future?

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The environmental benefit:Eco-Audit and DIN EN ISO 14001 You must have a leadership positionif you want to have a positive impacton the environment – from each andevery perspective. This is the reasonthat we not only develop well-provenconcepts for energy-saving motors,but we also ensure that our produc-tion facilities have the highest degreeof environmental compatibility. Forinstance, our motor plant in BadNeustadt is already participating inthe stringent demands of the Eco-Audit and has been certified accord-ing to DIN EN ISO 14001. This clearlyproves our ongoing commitment toenvironmental management at thehighest level. For example, we onlyuse environmentally-friendly cleaningagents in production, we recycle oursolvents by distillation and save ener-gy using heat-recovery systems. Byusing natural gas heating, we havealso been able to clearly reduce CO2

emission levels.

The quality benefit: DIN EN ISO9001 quality managementEvery chain is as strong as its weak-est link. At Siemens we take qualityseriously. Not only because it is partof our tradition – but also becausewe are convinced of its benefits. Theresult of this commitment: the covet-

ed DIN EN ISO 9001 certificate. Thiscertifies that we fulfill the stringentquality management requirementsacross the board – worldwide – for allof our production facilities and for allmotors.

The benefit to the “Bottom Line”:higher efficiencyOur energy-saving motors have up to45% less power losses, achieved invarious ways:

• Increased active material (iron,copper and aluminum)

• Improved magnetic steel quality• Optimized ventilation/cooling

system• CAD-based product optimization • Improvements to technical detail

with Siemens know-how• Development and testing in our

own certified measuring and testing laboratories

A clear comparison: rotorsand stators of our EFF1energy-saving motors havedecisively more activematerial than conventionalstandard motors.

Today, the awareness of the environment and energy savings is as high as never before. Conferences

on the climate, increasing fuel costs and environmental taxes underline the trend. Naturally, this trend

is not only driven by increased awareness about energy saving, but also as a result of international

political activities, e.g. the EC/CEMEP efficiency classification and the EPACT legislation in the US.

This means that manufacturers and users not only have a responsibility to sparingly use valuable

energy resources – but it has also become an economic necessity. It is of no surprise therefore that

Siemens places considerable significance on optimum use of materials, high efficiency and long

lifetime when developing our energy-saving motors. Our energy-saving motors play an important

role in the reduction of CO2 emissions, and in so doing the protection of the environment.

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Brighter days for the environment

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For years now, there has been an important indicator when selecting a consumer product –

the so-called efficiency class.This indicator is now being applied to electric motors.

The classification of electric motors has been simplified in 2000. Due to the work of the European

Commission and CEMEP (European Committee of Manufacturers of Electrical Machinery and

Electronics) all electric motors now have efficiency classes – and are appropriately labeled.

The right selection throughout Europe:the EC/CEMEP ClassificationThroughout Europe, the new efficien-cy classification according to EC/CEMEP makes it easier for users toselect energy-saving motors. Thedecisive advantage: the user canimmediately identify just how effi-cient the motor is – the same as withconsumer goods.

Motors are classified according toEC/CEMEP in three efficiency classes:• “EFF1” (high-efficiency motors)• “EFF2” (improved-efficiency

motors)• “EFF3” (standard motors)

Milestones on the way upThe international environmental con-ferences in Rio, Kyoto and BuenosAires as well as the increasing awareness about the scarcity of ourresources have cleared the way forpolitical intervention:

• In 1997, the US played a leadershiprole with the introduction of mini-mum efficiency levels in accor-dance with the EPACT legislation.

• As part of the EC project for “Ener-gy saving with electric drives”,renowned European motor manu-facturers, belonging to the CEMEPCommittee, signed a voluntaryagreement to designate the effi-ciency classes of electric motors.

• Part of this agreement is that Euro-pean motor manufacturers have vol-untarily agreed to reduce the mar-ket share of EFF3 motors by atleast 50% by 31.12.2003.

Starting in 2000, the efficiency classwill be stamped on the rating plateand specified in the documentation.

95

90

85

80

75

701 10 100

PN/kW

% ηN

High-efficiencymotors

Improved-efficiencymotors

Classified in 3 efficiency classesaccording to the agreementbetween the EC and CEMEP

Standard motors

Motor efficiencies are classifiedaccording to EC/CEMEP in three class-es so that two characteristic curvesdefine three ranges.

EC/CEMEP for Europe – at a glance

StatusVoluntary agreement to – Classify motor efficiencies– Drastically reduce the market

share of EFF3 motors (standard motors)

Applies to2- and 4-pole 50-Hz squirrel-cage induction motors1.1 … 90 kW

Efficiency measurementbased on the segregated-lossmethod acc. to IEC 60034-2

EfficiencyTolerance acc. to IEC 60034-1

Designations required– Efficiency class stamped on the

motor rating plate– ηrated, η3/4-load and efficiency classes

are specified in the documentation

Proof Manufacturer’s declaration

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Motor selection made easy

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Time is money. In order that you don’t give too much away, we have developed an EDP tool for you.

This allows you to evaluate your energy-saving potential – quickly and individually.You need to be

able to do your arithmetic if you wish to purchase motors or overhaul used motors – you will then

know whether it really makes sense to use EFF1 energy-saving motors.

The tool includes various operator screens to calculate the energy cost savings.You can also – and

this is what is unique about the tool – engineer the complete plant using energy-saving motors and

then make a comparison so that you can evaluate the overall energy saving.

Use this webpage link to analyze theenergy-saving potential in your plantor system. The advantages willbecome quite clear:

• Reliable decision-making basis forplant owners/operators regardingthe question of whether to useEFF1 or EFF2 energy-saving motor.

• Well-founded cost-benefit analysisin order to analyze the energy-saving potential.

• Any comparison motor can be used to evaluate the economical benefits.

• The most efficient solution forcustomers to save.

One program for all casesOur energy-saving program providesthe user with the best support. Thevarious calculation models arereviewed in the following cases.

Your benefit:Effective immediately, you canoptionally make calculations for par-tial load operation in addition to fullload operation.

The “energy saving” address:http://www.ad.siemens.de/energiesparmotoren

Case 1:You can quickly identify whether, inthe future, it makes sense for you touse Siemens EFF1 energy-savingmotors instead of EFF2 motors. Inthis case, all of the data on Siemensenergy-saving motors are saved,including order numbers!

Our example:As plant owner/operator, you cansave up to 357 euro per year if youuse a 4-pole 11-kW EFF1 Siemensenergy-saving motor instead of anEFF2 motor. The additional capitalcost of the EFF1 energy-savingmotor is paid back in approximately 5 months.

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So that you don’t throw money away

Case 2:This is quite similar to case 1. Thedecisive difference: in this case,you can individually base your cal-culation on any comparison motor.

Our example:As plant owner/operator, from3000 operating hours per year, youcan save 143 euro on energycosts, if instead of a 15-kW motorin the future you use an EFF1energy-saving motor with thesame output.

Case 3:In this case, you can even simu-late equipping the complete plantwith the highest efficiency EFF1energy-saving motors instead ofconventional motors. This givesyou the optimum decision-makingbasis to evaluate the most cost-effective solution. In this case, thepower factor and reactive powerare separately displayed.

Our example:As plant owner/operator, by usingEFF1 energy-saving motors, youcan save 71,000 euro on energycosts per year. All of the machinesand the complete plant then runfar more efficiently than with con-ventional motors.

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The efficiency classification according to EU/CEMEP makes it easier for users throughout Europe to

select energy-saving motors. Within the scope of this classification and the increased demands on

the efficiency, we at Siemens have applied two essential measures.

Firstly, we have optimized our complete motor range with respect to efficiency class EFF1 (high effi-

ciency) and EFF2 (improved efficiency). Secondly, we have redeveloped the new innovative 1LG

energy-saving motors in grey cast iron in efficiency classes EFF1 and EFF2.

Plants fit for the futureWe have optimized the existingmotor series to align them with effi-ciency class EFF1 which means thatwe are one of the few motor suppli-ers worldwide with energy-savingmotors in the highest efficiency classEFF1. We are already providing cus-tomers with a motor platform forplants and systems which are fit forthe future.

A benchmark:1LG energy-saving motorsThe new three-phase inductionmotors in grey cast iron offer a wholeseries of highlights. Here are the mostimportant advantages at a glance:

• Increased lifetime as a result ofimproved bearing design as well as a bigger grease compartment up to 50%

• Smooth running quality both inoperation and on start-up

• Universally applicable • Reduced maintenance costs as a

result of increased lubrication inter-vals (20,000 to 40,000 h at KT 40)

• Standard grease can be used to an ambient temperature of –30 degrees Celsius (previously,–20 degrees Celsius)

• Modular mounting concept: brake,pulse encoder and separately-driven fan can be mounted on-site(exception: the brake must bemounted in the factory)

• All of the most commonly usedpole numbers and types of con-struction are available

• Comprehensive range of options

An overview of our range:*

Improved Efficiency EFF2Aluminum:• 1LA7 2-pole: 0.09 kW to 18.5 kW • 1LA5 2-pole: 22 kW to 45 kW

4-pole: 0.06 kW to 15 kW 4-pole: 18.5 kW to 45 kW6-pole: 0.09 kW to 11 kW 6-pole: 15 kW to 30 kW

Grey cast iron:• 1LG4 2-pole: 22 kW to 37 kW • 1LA6 2-pole: 45 kW to 160 kW

4-pole: 18.5 kW to 30 kW 4-pole: 37 kW to 160 kW6-pole: 15 kW to 22 kW 6-pole: 30 kW to 132 kW

High Efficiency EFF1/EPACTAluminum:• 1LA9 2-pole: 0.09 kW to 37 kW

4-pole: 0.06 kW to 30 kW6-pole: 0.75 kW to 22 kW

Grey cast iron:• 1LG6 2-pole: 22 kW to 37 kW • 1LA6 2-pole: 45 kW to 160 kW

4-pole: 18.5 kW to 30 kW 4-pole: 37 kW to 160 kW6-pole: 15 kW to 22 kW 6-pole: 30 kW to 132 kW

We are successively extending thisrange up to frame size 315 L so thatthe newly developed series of ener-gy-saving motors will soon be com-plete. The current 1LA6 energy-savingmotors will continue to be availableuntil the 1LA6 frame sizes arereplaced by the 1LG series.

It goes without saying that our ener-gy-saving motors have the samemounting and connection dimensionsas conventional motors. This meansthat they are fully compatible, bothmechanically and electrically. Forsome frame sizes, the motors arelonger and when replacing motors,a check should always be made.

All of our energy-saving motors arean integral part of Totally IntegratedAutomation (T.I.A.) and can be inte-grated into any drive and automationenvironment via AC drive inverterswith PROFIBUS-DP® coupling.

* EU/CEMEP efficiency classification only applies to 2- and 4-pole motors in the output rangefrom 1.1 to 90 kW.

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The superlative new product range

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Siemens motors offer far more than what the specifications call for. For instance, our energy-saving

motors not only fulfill the relevant IEC standards, but also the tough EPACT US legislation.This legis-

lation specifies that minimum efficiencies must be maintained for motors which are directly or indi-

rectly imported into the US — which means that they are a lucrative entry ticket into the North Amer-

ican market for export-oriented customers.

Our 60-Hz EPACT motor series is, as standard, electrically designed according to NEMA MG1 and is

an established part of the Siemens product range. EPACT motors with NEMA dimensions can also

be supplied from our NAFTA-based motor plants.This means that our customers can select from a

complete range of optimum energy-saving motors which can be imported into the US market.

Special features for export to the USAThe efficiency must be measuredand certified by a test laboratory rec-ognized by NVLAP.

The following procedure must be observed:• The manufacturer must send a Dec-

laration of Conformity from a certi-fied test laboratory to the Depart-ment of Energy. The manufacturerthen receives a certification num-ber (“CC Number”).

• The nominal efficiency at full loadand the CC No. must be stampedon the rating plate. An “ee” symbolcan be stamped as an option.

• The import documents and all ofthe advertising materials mustspecify the CC No. and the nominalefficiency.

Special features for export to CanadaAll motors, which are not intendedfor re-export, must fulfill the efficien-cy regulations, based on the CSA-C390-M1985 Standard. This meansthat manufacturers must obtain a cer-tificate through the CSA International,Underwriters Laboratories Inc. oranother recognized organization.

The successful certification must bepublished in three ways:• A so-called “energy verification

mark” must be displayed on themotor.

• An energy-efficiency report mustbe passed on to National Re-sources Canada.

• A specific text has to be included in the customs documentation de-scribing the application of the ener-gy-saving motor.

EPACT/CSA for North America at a glance

StatusMinimum efficiencies stipulated by legislation

Applies to2-, 4- and 6-pole 60-Hz squirrel-cage motors1… 200 HP (0.75 … 150 kW)

Efficiency measurementBased on IEEE 112 B

Efficiency Nominal value ηaccording to NEMA MG1

Designations requiredEfficiency ηN

on the rating plate

ProofFrom a certified measuring laboratory

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EPACT – your gateway to the world

http://www.ad.siemens.de/energiesparmotoren

Automation and DrivesDivision Standard DrivesP. O. Box 32 69, D-91050 ErlangenGermany

Siemens Aktiengesellschaft

Subject to change without prior notice

Order No. E80001-A0020-P220-X-7600Printed in Germany Dispostelle 21505/SEK 3035121D6139 MK.SD.SM.SDSM.52.0.02 WS 120010.

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