Energy Efficient AC Motors

Transcription

1 Smart Solutions. Strong Relationship. Energy Efficient AC Motors IE Efficiency class a green solution...

2 Crompton Greaves APEX SERIES Crompton Greaves (CG) is part of the US$ bn Avantha Group, a conglomerate with an impressive global footprint. Since its inception CG has been synonymous with electricity. CG s India operations were established in 197, and since then the company has retained its leadershi p position in the management and application of electrical energy. Today, Crompton Greaves India s largest private sector enterprise. It has diversified extensively and is engaged in designing, manufacturing and marketing technologically advanced electrical products and services related to power generation, transmission and distribution, besides executing turnkey projects. The company is customer-centric in its focus and is the single largest source for a wide variety of electrical equi pments and products. With several international acquisitions, Crompton Greaves is fast emerging as a first choice global supplier for high quality equi pment through its business groups viz; Power Systems : Transformer Switchgear Power Quality Engineering Projects Industrial Systems : Motors Alternators Railway Signalling Drives Stampings

3 APEX SERIES INTRODUCTION Crompton Greaves Ltd As one of the world s leading engineering corporations,cg provides end-to-end solutions,helping its customers to use electrical power effectively and to increase industrial productivity with sustainability. CG was established in 197 in India; and,since then the company has retained its leadership position in the management and application of electrical energy. CG is leading manufacturer of electric motors,with motor solutions,which benefits a wide range of customers. Our products are used in almost every industrial application including general manufacturing, petrochemicals, food processing, pharmaceuticals where they drive fans, pumps, compressors,conveyors,lifts and cranes,amongst other things Our core competencies lie in our design facility conforming to the international quality standards. We make continuous effort,to bring out the latest,most advanced product into marketplace. We continuously add many new services,features and introduce new solutions so as to ensure complete customer satisfaction. Apex Series Apex IE series is a green solution by CG to save energy,as growing cost of energy calls for power savings at each possible step of manufacturing. Electric motor driven systems used in industrial process consume about 70% of electricity. These motors are complying with new efficiency requirements of IEC-0:8 IS615:011 standard. Apex aluminium motor range covers ac squirrel cage induction motors with output from 5kW to 7.50 kw in frame sizes GD80 TO GD1M. Apex series cast iron range covers ac squirrel cage induction motor with out put from 5 kw to kw in frame NG80 to ND55LX. They are being used in various range of application from food processing to chemical & heating to refrigeration. Quality assurance Stringent quality procedures are observed from first design to finished product in accordance with the ISO9001 documented quality systems. All of our factories have been assessed to meet these requirements,a further assurance that only the highest possible standards of quality are accepted. Benefits of Apex Series Motors - High efficient at low running cost - Low vibration and noise - High torque with smooth acceleration Multi Mount (Aluminium motor range upto 7.5 kw)- By simply changing the position of feet,user is able to convert right,left or top terminal box position and by changing the standard end shield user can change it for flange or face version. IEC -0:8 / IS Specifications International Electro technical Commission (IEC) standard IEC -0:8 defines energyefficiency (IE code) classes for single speed,three-phase,50 and 60 Hz induction motors. The efficiency levels defined in IEC -0 are based on test methods specified in IEC --1:7 The standard defines three International energy efficiency classes (IE classes). - IE1 = Standard efficiency (EFF in the former European classification scheme) - IE = High efficiency (EFF1 in the former European classification scheme and equivalent to EPAct in the USA for 60 Hz) - IE = Premium efficiency (equivalent to NEMA Premium in USA for 60 Hz) The standard covers almost all motors (for example standard,marine,brake motors,geared motor) - Single speed,three-phase,50 Hz and 60 Hz -, or 6 poles - Rated output from 5 to 75 kw - Rated voltage up to 00 V - Duty type S1 (continuous duty) or S (intermittent periodic duty) with a rated cyclic duration factor of 80 percent or higher - Capable of operating direct online The following motors are excluded from the standard : -Motors made solely for converter operation. -Motors completely integrated into a machine (for example,pump,fan or compressor)that can not be tested separately from the machine. -Motors rated for duty cycles S and above except if an equivalent S1 duty is specified by the driven equipment manufacturer. Additional Specifications of IS The motors are capable of delivering rated output with, a) terminal voltage differing from its rated value by not more than ± %,or b) frequency differing from its rated value by not more than ± 5%,or c) the sum of absolute percent variations of (a) & (b) not exceeding % The fixing dimensions and shaft extensions of motors are conforming to the values specified in IS 1 and IS. The relationship between output,in k W and frame number are according to IS 1. Apart from efficiency,indian Standard defines following performance parameters for IE motors 1) Full load Speed ) Full load Current ) Breakaway Torque ) Breakaway Current IEC --1:7 / IS (Part / sec 1) Specification The standard introduces new rules concerning the testing methods to be used for determining losses and efficiency. It offers two ways of determining efficiency; the direct and indirect methods. The standard specifies the following parameters for determining efficiency using the indirect method: 1) Reference temperature ) Four options for determining PLL (additional load losses): a. Measurement- PLL calculated from load tests b. Estimation- PLL at assigned value.5% -1.0% of input power at rated load between 0.1 kw and 00 kw c. Mathematical calculation - Eh star -alternative indirect method with mathematical calculation of PLL d. PLL from removed rotor and reverse rotation test Winding losses in stator and rotor are determined at (5º C + actual temperature rise measured) The resulting efficiency values differ from those obtained under the previous IEC testing standard, IEC -:1996. It must be noted that efficiency values are only comparable if they are measured using the same method. REFERENCE STANDARDS Standards IEC -1-0 IEC -0:8 Descri ption Rotating electrical machines - Rating & Performance Rotating electrical machines - IE Code for Efficiency Classes IEC --1:7 Rotating electrical machines - Determination of Losses & Efficiency IEC -5:6 IEC -9:7 IEC -1:7 IEC 7-1:1991 IS 1:197 IS -198 Rotating electrical machines - Degrees of protection Rotating electrical machines - Noise Limits Rotating electrical machines - Vibration Limits Rotating electrical machines - Dimensions Rotating electrical machines - Dimensions foot mounted Rotating electrical machines - Dimensions flange mounted 1

4 INTRODUCTION APEX SERIES IE Classes - pole 97 Efficiency values defined in IEC -0:8 / IS Pole High Efficiency 6 Pole Pole Pole IE Premium Efficiency Pole Pole 6 Pole Output IE 9 Efficiency % kw IE1 Standard Efficiency Pole Pole IE 87 IE IE IE1 0,75 1,1 1,5, Any efficiency value between IE1 and IE values, is to be considered as IE1 class for motors. ) Any efficiency value between IE and IE values, is to be considered as IE class for motors. ) The full load efficiency of any individual motor, when tested at rated voltage and frequency, shall not be less than the rated efficiency minus the tolerances in accordance with IEC -1. 5) Energy efficient cage induction motors are typically built with more active material, i.e longer core length and/or greater core diameter in order to achieve the higher efficiency. For these reason the starting performance of energy efficient motors differs somewhat from motors with a lower efficiency. On average the locked rotor current increases by %-15% for motors from one energy efficiency class compared to motors of the next higher class with the same output power. Individually,this difference depends on the construction princi ple of the motor and should be checked with manufacturer when replacing motors in an existing installation. It must be ensured that the control protective device is properly sized and setup. 6) 5,5 7, , Output kw NOTE :1) It must be noted that efficiency values are only comparable if they are measured using the same method. ) As per IEC-0 : 8 motors specially designed, For special requirement of the driven machine (e.g heavy starting duty, special torque stiffness and/or breakdown torque characteristics, large number of start/stop cycles,very low rotor inertia) For special characteristics of grind supply (e.g limited starting current, high tolerances of voltage and/or frequency) For special ambient conditions (e.g very low ambient temperature,smoke extraction motors, high altitues of installation)

5 APEX SERIES ENERGY & CO ISSUES Most electricity today is generated by burning fossil fuels and producing steam which is then used to drive a steam turbine that in turn,drives an electrical generator. More serious are concerns about the emissions that result from fossil fuel burning. Burning them results in the conversion of carbon to carbon dioxide, which is then released into the atmosphere. The estimated CO emission from the world s electrical power industry is billion tonnes yearly. This results in an increase in the Earth s levels of atmospheric carbon dioxide, which enhances the greenhouse effect and contributes to global warming. The linkage between increased carbon dioxide and global warming is well accepted though fossil-fuel producers vigorously contest these findings. Estimates of Technical Savings Total Energy & Feedstock Savings Potential EJ/yr Mtoe/Yr % Mt CO/yr Sectoral Improvement Chemical / Petrochemicals Iron and steel Cement Pulp and Paper Aluminium Other non-metalic metals Minerals and non-ferrous System/life cycle improvement Motor System Combined head and power stem system Process integration Increased recycling Energy Recovery Total Global improvement potentialshare of industrial energy use and CO emissions According to Environment Canada : Fossil fuel-fired electric power plants emit carbon dioxide, which may contribute to climate change. In addition, the sector has significant impacts on water and habitat and species. In particular,hydro dams and transmission lines have significant effects on water and biodiversity Here are some more starting predictions of what changes to climate could cause,and how we ll be affected: Low-High Potential Major floods may now start to happen every or 0 years rather than once or twice a century Global sea levels could rise by almost a meter by 0 Exposure to higher levels of UV light could cause an extra 5,000 deaths a year from skin cancer Climate change may drive more of a quarter of land animals and plant species to extinction Total energy & Feedstock Savings Potentials The conclusion is that manufacturing industry can improve its energy efficiency by an impressive 18 to 6%,while reducing the sectors CO emission by 19 to %,based on proven technology. Identified improvement options can contribute 7 to % reduction in global energy and process-related CO emissions. The single most important category is motor systems, followed by chemicals/petrochemicals on an energy savings basis. The highest range of potential sectoral savings for CO emissions is in cement manufacturing. The savings potential under the heading system/life cycle improvements is larger than the individual sub-sectors in part because those options apply to all industries % 18-6 % 19- % Reference : Tracking industrial energy efficiency and CO emissions Conserve Energy for a Brighter Future..!

6 APEX SERIES INTRODUCTION Apex series Aluminium motors (GD Frames) Range Output Frames Poles 5 kw to 7.50 kw GD 80 TO GD 1,,6 Specification Frame sizes Enclosure Mounting option Terminal box position Standard Product 80 to 1 IP55 Foot (B) Top Option - IP56, IP65 Flange (B5), Face (B1) or Pad (B0) Left hand side (LHS), Right hand side (RHS) Voltage Frequency Cooling Lubrication Insulation Temperature rise Paint color Fan cover Thermal protection Anti condensation heaters Inverter Duty (with derate) Ambient temperature DC brake Altitude kw and below: 15 / 00 Y Y.7 kw and above: 15 / Hz IC11 Frame 80 to 1 double-shielded bearings Class F Class B Gentian blue (RAL 50) Steel - - Variable Torque - :1, Constant Torque - :1-0 C to + 50 C - 00m 60 Hz IC - 80 Y Class H Class F On request Plastic 80 to 1 frames 1 frame Alternative speed range Higher than 50 C 80 to 1 frames Higher than 00 m Others on request The above specification and options give a brief summary of features available for the Apex aluminium range. For a full listing of optional features, please contact CG sales

7 INTRODUCTION APEX SERIES Apex series cast Iron motors.(ng,nd Frames) Range Output Frames 5 kw to kw NG80 to NG1M ND160M to ND55LX Poles,,6 Specification Standard Product Option Frame sizes 80 to 55 - Enclosure IP55 IP56 Mounting option Foot (B) mounting feet integral with the Stator body Flange (B5), Face (B1) - upto 1 Frame Terminal box position Right hand side (RHS) Top, left hand side (LHS) Voltage kw and below: 15.7 kw and above: / 00 / 690. Others on request 80 Frequency 50 Hz 60 Hz Cooling IC11 Lubrication Frame 80 to double-shielded bearings IC - Frame to 55 online Greasing Insulation Class F Class H Temperature rise Class B Class F Paint colour Gentian blue (RAL 50) On request Fan cover Steel - - heaters 80 to 55 frame 1 to frame Inverter Duty (with Variable Torque - :1, derate) Constant Torque - :1 (for frame 80 to 1) Alternative speed range Ambient temperature - 0 C to + 50 C - Higher than 50 C; Less than -0 C DC brake Altitude 00m Higher than 00 m Thermal protection 80 to 55 frame Anti condensation 80 to frame The above specification and options give a brief summary of features available for the Apex cast iron range. For a full listing of optional features, please contact CG sales 5

8 APEX SERIES DIMENSIONS - ALUMINIUM TEFC PHASE FOOT MOUNTED ALUMINIUM INDUCTION MOTORS L ±5 AD = ED = CABLE ENTRY ØAC HD' HD HD'' -HOLES ØK H -HOLES ØK H AA A ±0.5 AB HA E ±0.5 C ±1 B ±0.5 BB AA A ±0.5 AB HA CABLE ENTRY DIMENSIONS ARE AS PER IEC 7-1 ALL DIMENSIONS ARE IN mm. EARTHING TERMINAL GD 80 GD90S GD90L GD0L GD1M GD1S GD1M General Terminal box Type A B C H K L AA AB AC BB HA HD TBW TBH KK FLANGE MOUNTING IM - B5 FACE MOUNTING IM - B1 SHAFT DIA IM B5 MOUNTING IM B1 MOUNTING SHAFT DIMENSIONS TYPE GD80 GD90S/L GD0L GD1M GD1S/M M N P S T LA M N P S T LA TYPE D E F G ED DH M6 M8 M8 M8 M GD80 GD90S/L GD0L GD1M GD1S/M M6X16 M8X19 MX MX MX8 6 * Some features may be different and may not be a part of standard product.

9 APEX SERIES DIMENSIONS - CAST IRON TEFC, PHASE FOOT MOUNTED CAST IRON INDUCTION MOTORS (NG80 to NG1) HD'' CABLE ENTRY General TYPE NG80 NG90S NG90L NG0L NG1M NG1S NG1M Terminal box A B C H K L AA AB AC AD BB HA HD TBW TBH KK X X 0 1 X X X X X 5 FLANGE MOUNTING IM - B5 FACE MOUNTING IM - B1 SHAFT DIA IM B5 MOUNTING IM B1 MOUNTING SHAFT DIMENSIONS TYPE M N P S T LA M N P S T LA TYPE D E F G ED DH NG M6 9 NG M6X16 NG90S/L M8 9 NG90S/L M8X19 NG0L M8.5 NG0L MX NG1M M8.5 1 NG1M MX NG1S/M M.5 1 NG1S/M MX8 * Some features may be different and may not be a part of standard product. 7

10 DIMENSIONS - CAST IRON APEX SERIES TEFC, PHASE FOOT MOUNTED CAST IRON INDUCTION MOTORS RINGED DIMENSIONS ARE AS PER IEC:7-1 ALL DIMENSIONS ARE IN mm * Some features may be different and may not be a part of standard product. 8

11 DIMENSIONS - CAST IRON APEX SERIES TEFC, PHASE FOOT MOUNTED CAST IRON INDUCTION MOTORS RINGED DIMENSIONS ARE AS PER IEC:7-1 ALL DIMENSIONS ARE IN mm * Some features may be different and may not be a part of standard product. 9

12 APEX SERIES DIMENSIONS - CAST IRON TEFC, PHASE FOOT MOUNTED CAST IRON INDUCTION MOTORS (FRAME ND55LX) RINGED DIMENSIONS ARE AS PER IEC:7-1 ALL DIMENSIONS ARE IN mm * Some features may be different and may not be a part of standard product.

13 DIMENSIONS - CAST IRON APEX SERIES TEFC, PHASE FLANGE MOUNTED CAST IRON INDUCTION MOTORS RINGED DIMENSIONS ARE AS PER IEC:7-1 ALL DIMENSIONS ARE IN mm * Some features may be different and may not be a part of standard product. 11

14 DIMENSIONS - CAST IRON APEX SERIES TEFC, PHASE FLANGE MOUNTED CAST IRON INDUCTION MOTORS RINGED DIMENSIONS ARE AS PER IEC:7-1 ALL DIMENSIONS ARE IN mm * Some features may be different and may not be a part of standard product.

15 APEX SERIES DIMENSIONS - CAST IRON TEFC, PHASE FLANGE MOUNTED CAST IRON INDUCTION MOTORS (FRAME ND55LX) RINGED DIMENSIONS ARE AS PER IEC:7-1 ALL DIMENSIONS ARE IN mm Frame D E ED F GD G Y AD A C L M Tol N T o l P S T L A L B HB POLE : ND55LX 75.00/ /.00/ 67.5/ M0X / / POLE :,6 0.05/ 8.00/ 16.00/ 90.0/ 71.0/ / ND55LX 160 MX Frame D E E D F GD G Y A D A C L M Tol N tol P S T LA LB HB * Some features may be different and may not be a part of standard product. 1

16 APEX SERIES PERFORMANCE - ALUMINIUM MOTORS PERFORMANCE DATA FOR ALUMINIUM MOTORS Efficiency values complying to IE class of IEC -0:8/IS615:011 CG PRODUCT RATED POWER FRAME FULL LOAD CURRENT FL FLT EFFICIENCY POWER FACTOR D.O.L STARTING PULLOUT GD CODE IN SPEED kw hp 80V 00V 15V RPM MN SSC S TT POT kg.m FL /L 1/L FL /L 1/L %FLA %FLT %FLT kg.m Pole - 0 Synchronous rpm 5KEG 5 1 GD80M KEG 1.1 GD80M KEG GD90S KEG. GD90L KEG GD0L KEG.7 5 GD0L KEG 5.5 GD1M KEG GD1M KEG GD1S KEG 7.5 GDIS Pole Synchronous rpm 5KEG 5 1 GD80M KEG 1.1 GD90S KEG GD90L KEG. GD0L KEG GD0L KEG.7 5 GD1M KEG 5.5 GD1M KEG GD1S KEG 7.5 GD1M Pole - 00 Synchronous rpm 5KEG6 5 1 GD90S KEG6 1.1 GD90L KEG6 GD0L KEG6. GD1M KEG6 GD1S KEG6.7 5 GD1S KEG6 5.5 GD1M * Output and Frames are as per IS 1 * Tolerances are applicable as per IEC -1 : 0 Full load current indicated are given for respective voltage designs 1

17 APEX SERIES PERFORMANCE - CAST IRON MOTORS PERFORMANCE DATA FOR CAST IRON MOTORS Efficiency values complying to IE class of IEC -0-8/IS615:011 CG PRODUCT RATED POWER FRAME FULL LOAD CURRENT FL FLT EFFICIENCY POWER FACTOR D.O.L STARTING PULLOUT GD CODE IN SPEED kw hp 80V 00V 15V RPM MN kg.m FL /L 1/L FL /L 1/L SSC S TT POT %FLA %FLT %FLT kg.m Pole - 0 Synchronous rpm 5KE 5 1 NG KE 1.1 NG KE. NG90S KE. NG90L KE NG0L KE.7 5 NG0L KE 5.5 NG1M KE NG1S KE 7.5 NG1S KE 9..5 ND160M KE ND160M KE 15 0 ND160M KE ND160L KE 0 ND180M KE 0 0 NDL KE 7 50 NDL KE 5 60 NDM KE NDMX KE 75 0 ND80M KE 90 0 ND80M KE ND15S KE 1 ND15M KE 160 ND15LX KE ND15LX KE 68 ND15LX KE ND55LX KE 5 ND55LX * Output and Frames are as per IS 1 * Tolerances are applicable as per IEC -1 : 0 Full load current indicated are given for respective voltage designs 15

18 APEX SERIES PERFORMANCE - CAST IRON MOTORS PERFORMANCE DATA FOR CAST IRON MOTORS Efficiency values complying to IE class of IEC -0-8/IS615:011 CG PRODUCT RATED POWER FRAME FULL LOAD CURRENT FL FLT EFFICIENCY POWER FACTOR D.O.L STARTING PULLOUT GD CODE IN SPEED kw hp 80V 00V 15V RPM MN kg.m FL /L 1/L FL /L 1/L SSC S TT POT %FLA %FLT %FLT kg.m Pole Synchronous rpm 5KE 5 1 NG KE 1.1 NG90S KE. NG90L KE. NG0L KE NG0L KE.7 5 NG1M KE 5.5 NG1M KE NG1S KE 7.5 NG1M KE 9..5 ND160M KE ND160M KE 15 0 ND160L KE ND180M KE 0 ND180L KE 0 0 NDL KE 7 50 NDS KE 5 60 NDM KE NDMX KE 75 0 ND80S KE 90 0 ND80M KE ND15S KE 1 ND15M KE 160 ND15LX KE ND15LX KE 68 ND15LX KE ND55LX KE 5 ND55LX * Output and Frames are as per IS 1 * Tolerances are applicable as per IEC -1 : 0 Full load current indicated are given for respective voltage designs 16

19 APEX SERIES PERFORMANCE - CAST IRON MOTORS PERFORMANCE DATA FOR CAST IRON MOTORS Efficiency values complying to IE class of IEC -0-8/IS615:011 CG PRODUCT RATED POWER FRAME FULL LOAD CURRENT FL FLT EFFICIENCY POWER FACTOR D.O.L STARTING PULLOUT GD CODE IN SPEED kw hp 80V 00V 15V RPM MN kg.m FL /L 1/L FL /L 1/L SSC S TT POT %FLA %FLT %FLT kg.m 6 Pole - 00 Synchronous rpm 5KE6 5 1 NG90S KE6 1.1 NG90L KE6. NG0L KE6. NG1M KE6 NG1S KE6.7 5 NG1S KE6 5.5 NG1M KE ND160M KE6 7.5 ND160M KE ND160M KE ND160L KE ND180L KE NDL KE6 0 NDL KE6 0 0 NDM KE NDM KE ND80S KE ND80M KE ND15S KE ND15M KE ND15M KE6 1 ND15L KE6 160 ND15LX KE ND55L * Output and Frames are as per IS 1 * Tolerance are applicable as per IEC -1:0 Full load current indicated are given for respective voltage designs NOTE : As the design and manufacture of Crompton Greaves electrical equipment are subject to constant improvement, the product supplied may differ in some details from the specifications and illustrations given in this booklet. For more details, contact CG Sales. 17

20 APEX SERIES BEARINGS & SHIPPING DETAILS Bearing Details Approximate shi pping dimensions & Weights Bearings Frame Pole Driving End Non-Driving End ALUMINIUM MOTORS GD80 ALL 60ZZ ZZ GD90 ALL 605ZZ 60ZZ GD0 ALL 606ZZ 605ZZ GD1 ALL 606ZZ 605ZZ GD1 ALL 608ZZ 605ZZ CAST IRON MOTORS NG80 NG90 NG0L NG1 NG1 ND160 ND180 ND ND ND ND80 ND80 ND15 ND15 ND55 ND55L ND55LX ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL &UP &UP &UP &UP 60ZZ 605ZZ 606ZZ 606ZZ 608ZZ 609ZZ 6ZZ 6ZZ 61ZZ ZZ 60ZZ 605ZZ 605ZZ 605ZZ 609ZZ 6ZZ 6ZZ 61ZZ kg FRAME NET WT GR WT ALUMINIUM GD80 9 GD90S 1 1 GD90L GD0L 7 9 GD1M 6 GD1S 5 56 GD1M 5 56 CAST IRON NG NG90S 6 NG90L 5 9 NG0L 7 NG1M 5 0 NG1M ND160M ND160L 1 17 ND180M ND180L 0 8 NDL 5 91 NDS 50 0 NDM NDM ND80S ND80M 81 ND15S ND15M ND15L ND55L ND55LX 00 5 Packing case details Packing case Frame L X B X H Packing case type 80 60XX0 Carton 90 90X0X60 Carton 0 60X0X85 Carton 1 60X0X85 Carton 1 85X50X0 Carton X585X615 Metallic X685X60 Metallic 00X775X665 Metallic 50X800X75 Metallic 1150X95X850 Metallic 80 1X975X890 Metallic NOTE: - Insulated bearing and Rollers bearings for frame & above are available on request X1170X0 1870X15X1180 Metallic Metallic 18

21 APEX SERIES NOISE LIMITS & MOUNTINGS Noise Limits (IEC -9) - 7 Maximum A-weighted sound power level, Iwa in db, at no-load (For single speed three-phase cage induction motor IC111) Shaft height. H mm pole pole 6 pole MOUNTING ARRANGMENTS (IEC -7) HORIZONTAL VERTICAL FIGURE FIGURE REF B B5 FRAME WITH FEET WITHOUT FEET SHAFT HORIZONTAL HORIZONTAL MTNG BASE OR RAILS FLANGE TYPE D REF V1 V5 FRAME WITHOUT FEET WITH FEET SHAFT FACE VERT. DOWN FACE VERT. DOWN MTNG FLANGE TYPE D BASE OR RAILS FIGURE REF B5 B1 FRAME WITH FEET & WITHOUT FEET FLANGE SHAFT HORIZONTAL HORIZONTAL MTNG BASE OR FLANGE TYPE C FLANGE TYPE D REF V15 V FRAME WITH FEET WITHOUT FEET SHAFT FACE VERT. DOWN FACE VERT. UP MTNG WALL OR FLANGE FLANGE TYPE D TYPE D FIGURE REF B B6 FRAME WITH FEET WITH FEET SHAFT HORIZONTAL HORIZONTAL MTNG BASE OR WALL FLANGE TYPE C REF V6 V6 FRAME WITH FEET WITH FEET SHAFT FACE VERT. UP FACE VERT. UP MTNG WALL OR FLANGE BASE OR RAILS TYPE D FIGURE REF B7 B8 FRAME WITH FEET WITH FEET SHAFT HORIZONTAL HORIZONTAL MTNG WALL CEILING REF V18 V19 FRAME WITHOUT FEET WITHOUT FEET SHAFT FACE VERT. DOWN FACE VERT. UP MTNG FLANGE TYPE C FLANGE TYPE C * For installation of foot mounted motor on the wall,additional support must be provided. These mountings are shown for information purpose only, for availability please contact CG sales 19

22 APEX SERIES FAQ FREQUENTLY ASKED QUESTIONS 1. What is IE? IE is International Efficiency with class 1, & i.e. IE1, IE & IE. The new standard IEC -0:8/IS615:011 defines these classes. At the same time,with the IEC --1:7/IS615:011 standard,a new procedure for the determination of efficiency has been introduced which also contributes to international harmonization.. This standard is made to unify motor testing procedures, determination of efficiency and product labeling requirements. This is to enable motor user worldwide to easily identify premium efficiency products. New efficiency classes defined by IEC- 0 and its equivalence with other standards/nomenclature Efficiency % High efficiency Low efficiency IE IE IE IE1 EFF1 EFF Old CEMEP Directive IE Premium Efficiency IE High Efficiency IE1 Standard Efficiency IEC motors IE Classes - pole Output kw NEMA Premium EPAct NEMA motors 0,75 1,1 1,5, 5,5 7, , Why improving motor efficiency is important? Over 70 % of all electrical energy consumed in industries is used by electric motors. Improving the efficiency of electric motors and the driven equipment can save energy,reduce operating costs, and improve our nation's productivity. Energy efficiency should be a major consideration when you purchase or rewind a motor. The annual energy cost of running a motor is usually many times greater than its initial purchase price. For example,even at the relatively low energy rate of Rs.0.085/kWh,a typical 15 kw continuously running motor uses almost Rs.,000 worth of electricity annually,about six times its initial purchase price.. What efficiency values should I use when comparing motors? When comparing motor efficiencies,be sure to use a consistent measure of efficiency. Nominal efficiency is best. Nominal efficiency is an average value obtained through standardized testing of a population of motors. Minimum guaranteed efficiency, which is based on nominal efficiency, is slightly lower to take into account typical population variations. Minimum guaranteed efficiency is also less accurate, because the value is rounded. Other efficiency ratings, including apparent and calculated, should not be used... When should I consider buying an energy-efficient motor? Energy-efficient motors should be considered in the following circumstances: For all new installations - When purchasing equipment packages, such as compressors, HVAC systems, and pump - When major modifications are made to facilities or processes - Instead of rewinding older, standard efficiency units - To replace oversized and under loaded motors - As part of a preventive maintenance or energy conservation program. 5. Should I rewind a failed motor? Although failed motors can usually be rewound, it is often worthwhile to replace a damaged motor with a new energy-efficient model to save energy and improve reliability. At the time of calculating operating costs for rewound motors, deduct one efficiency point for motors exceeding 0 kw and two points for smaller motors. Have motors rewound only at CG authorized service centers that use low temperature bake out ovens,high quality materials,and a quality assurance program based on ISO Ask the repair shop to conduct a core loss or loop test as part of their rewind procedures. Select a new energy-efficient motor under any of the following conditions: - The motor is less than 0 kw - The cost of the rewind exceeds 65% of the price of a new motor. - The motor was rewound before year 0 6. What design factors should I consider when choosing a new motor? Motor size- Motors should be sized to operate with a load factor between 65% and 0%. The common practice of over sizing results in less efficient motor operation. For example,a motor operating at a 5% load is less efficient than a smaller motor that is matched to the same load. Of course,some situations may require over sizing for peak loads,but in such cases alternative strategies should be considered,such as a correctly sized motor backed up with a pony motor. Operating speed- Replacement is to done by energy efficient motors with a comparable full load speed for centrifugal load applications (pumps and fans). Induction motors have an operating speed that is slightly lower than their rated synchronous speed. For example,a motor with a synchronous speed of 1500 rpm will typically operate under full load at about rpm. Operating speed (full-load rpm) is stamped on motor nameplates. The difference between the synchronous speed and the operating speed is called slip. Slip varies with load and the particular motor model. Every pump and fan has a designed speed. Centrifugal pump and fan loads are extremely sensitive to speed variations; an increase of just 5 rpm can significantly affect the pump or fan operation, leading to increased flow, reduced efficiency, and increased energy consumption. Whenever a pump or fan motor is replaced,be sure to select a model with a full-load rpm rating equal to or less than that of the motor being replaced. Inrush current- Avoid overloading circuits. Energy-efficient motors feature low electrical resistance and thus exhibit higher inrush currents than standard models. The inrush current duration is too short to trip thermal protection devices, but energy-efficient motors equipped with magnetic circuit protectors can sometimes experience nuisance starting trips. 7. How to calculate energy savings and payback period? 5.5 kw pole standard IE1 motor is having efficiency 8.7 %. Where as Apex Series IE has 87.7 % Energy Savings (S) * Payback Period (P) * = W X L X C X N X( 0/Es-0/Ee) = 5.5 X 1 X 5.8 X 800 X (0/8.7-0/87.5) = 5785 per year = Ce/S X =.6 months W-Motor Rating in kw L-% load (1 for rated kw loading) C-Electricity Cost /kwh N-Number of working Hours per year * This may vary with the application and working hours Ee-Efficiency of IE motor Es- Efficiency of standard IE1 motor Ce-Cost of IE motor- Cost of IE1 motor i.e.( = ) 0

23 Contact Details - India APEX SERIES Northen Region Sales Office : Eastern Region Sales Office : New Delhi : rd Floor, Express Building, 9-, Bahadur Shah Zafar Marg, Near RTO Crossing, Delhi Phones : (011) 60 Jalandhar : Nr BSF Chowk, Ladowali Road, Jalandhar Phones : (0181) 051 Lucknow : Saran Chambers II, rd Floor, 5 Park Road, Lucknow Phones : (05) Jai pur : Church Road, P.O.Box No. 17, Jai pur Phones : (011) Kolkata : 50, Chowringhee Road, Kolkata Phones : (0) Bhubaneshwar : Janpath Tower, Third Floor, Ashok Nagar, Unit II, Bhubaneshwar Phones : (067) 518 Western Region Sales Office : Southern Region Sales Office : Mumbai : Kanjur Marg (E), Mumbai Phones : (0) Ahmedabad : , Sakar II, Near Ellis Bridge Police Station, Ahmedabad Phones : (079) 00 Pune : Premium Point, th Floor, Opp. Modern High School, Jangali Maharaj Road, Pune 5. Phones : (00) Indore : -B, Apollo Trade Centre, B Rajgarh Kothi, Mumbai-Agra Road, Indore Phones : (071) 99 Nagpur :, West High Court Road, Lal Bahadur Shastri Chowk, Dharampeth, Nagpur Phones : (07) 571 Rai pur : A-01 Crystal Arcade, Shankar Nagar Road, Near Lodhi para Square, Rai pur 91 Phones: (0771) 0190 Chennai : No. -A, MGR Salai, Kodambakkarn High Road, Nungambakkam, Chennai - 0. Phones : (0) 00 Banglore : J.P. Square, rd floor, No. 17 rd cross 5th main, Chamarajapet Bangalore 518 Phones: (080) Cochin : Cherupushpam Building, 5th Floor, -6, Shanmugham Road, Ernakulum, Cochin Phones : (08) 700 Secunderabad : th Floor, Minerva House, 9, Sarojini Devi Road, Secunderabad Phones : (00) 000 Regional Service Centers : North : rd Floor, Express Building, 9-, Bahadur Shah Zafar Marg, Near RTO crossing, Delhi Phones : (011) 60 East : 1, R.N.Mukherjee Road, Kolkata Phones : (0) West : Kanjur Marg (E), Mumbai Phones : (0) South : A, MGR Salai, Kodambakkam High Road, Nungambakkam, Chennai - 0. Phones : (0) NOTE : As the design and manufacture of Crompton Greaves electrical equi pment are subject to constant improvement, the product supplied may differ in some details from the specifications and illustrations given in this booklet. For more details contact nearest Branch Office. 1

24 Crompton Greaves Limited Contact Details- International CG INTERNATIONAL DIVISION Jagruti Building, nd Floor, Kanjurmarg(E), Mumbai Maharashtra (India) Phone : CG Drives & Automation Mörsaregatan SE- Helsingborg Sweden Phone : Fax : CG Drives & Automation Goethestraße 6 D-8855 Wernigerode Germany Phone : + 9 (0) Fax : + 9 (0) CG Drives & Automation Polakkers NX Bladel The Netherlands Phone : + 1 (0) Fax : + 1 (0) CG Electric Systems Hungary Zrt. Rotating Machine Business Unit, H-95 Budapest, Mariassy Utca 7. Phone : Fax : CG Drives & Automation North Shore Drive Miami Beach, FL 11 USA Phone : Fax : CG Drives & Automation Rm 9, Silver Centre 188 North Shanxi Road Putuo District Shanghai China 060 Phone : Fax : CG Sales Networks France S.A Sevice Commercial - Paris, 1, Boulevard Vauban, GUYANCOURT, FRANCE Phone : (+) Fax : (+) CG Sales Networks UAE Ltd. P. O. Box 570 Sharjah, UNITED ARAB EMIRATES Phone : Fax :

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