Guidance Document EP.NA. Premium Efficient Integral Motors
Table of Contents Overview...Section A Product Specifications...Section B Application Consideration for Motor Replacement...Section C Performance Differences... Section D Inertial Differences... Section E Gearmotor Start/Stop Service Factor Differences... Section F Dimensional and Weight Differences...
Section A Overview Table of Contents
Mandatory Requirement for Premium Efficiency Gearmotor As an ongoing effort to reduce United States carbon footprint, the Department of Energy (DOE) has a mandate to update the efficiency regulation of various products used in the United States. In May of 2014, the DOE issued a new ruling expanding the scope of the mandatory Minimum Efficiency Performance Standard (MEPS) for Induction Motors. The scope of the expansion includes previously exempt class of induction motors including gearmotors and brakemotors. The DOE has given motor manufacturers and motor importers two years to comply with this new requirement with a compliance date of June 1, 2016. After this compliance date, non-compliant motors cannot be manufactured in or imported into the United States. Motors already manufactured or imported prior to this date can continue to be sold in the US marketplace. Section A For further information on this ruling, please see the federal information on the website address shown below. http://www.regulations.gov/#!documentdetail;d=eere-2010-bt-std-0027-0117 The basic characteristics of the regulated motors are defined with the following specifications: Motor is a single-speed, induction motor Motor is rated for continuous duty (or IEC duty-type S1) Motor has a squirrel-cage rotor Motor operates on polyphase, 60Hz sinusoidal power Motor is rated for 600VAC or less. Motor is built with 2-pole, 4-pole, 6-pole or 8-pole configuration. Motor is built with 3-digit or 4-digit NEMA frame size (or IEC equivalent) or an enclosed 56 NEMA frame size (or IEC equivalent). Motor providing at least 1HP (0.746kW) but not greater than 500HP (373kW) Motor meets all of the performance requirements of a NEMA Design A, B, or C motor or of an IEC Design N or H electric motor. The minimum efficiency levels for the regulated motors will, in most cases, need to meet Premium Efficiency levels as defined by NEMA MG-1 standard. At 60Hz these are typically equivalent to IE3 efficiency levels defined by IEC standard 60034-30. DOE can apply significant penalties if motors manufactured or imported after the June 1, 2016 are installed in the United States. Penalties applies to the manufacturer or importer and can run up to $110 per motor per day, according to one recent presentation. Also, throughout the globe, many countries are mandating MEPS regulation or are updating the MEPS regulation to increase the efficiency levels. Sumitomo has prepared or is preparing products to meet these global requirements. In some cases the motor product may need to be certified and marked appropriately to be accepted for the target country. Please consult with the factory for more details on what is available to make sure that equipment can be exported and complies with the local requirements. Overview A-1
Section A Sumitomo Gearmotor Compliance Status Sumitomo gearmotors that have been supplied heretofore within the new regulated motor scope do not meet the efficiency levels required by the new ruling. Sumitomo is preparing the release of a new motor series (EP. NA) that complies with the new efficiency requirements set by the DOE. The new motor series will replace the existing motors which start to become unavailable as the new regulation goes into effect. The DOE ruling prevents further manufacture or importation of these older motors on June 1st 2016 date. The new motors will be certified by DOE to indicate compliance to the new DOE rule. Because the new motor series will be significantly different from the older series, motor users may need to carefully review the differences when replacing an older motor series with the new one. To meet the higher efficiency requirements, the new motor adopts a number of strategies to minimize losses while keeping the increase in size and cost reasonable. The new motor series is larger and heavier and has a higher moment of inertia when compared to the older motor series. You can also expect to see higher starting torque and starting current and other preference changes when compared with previously sold motors. A-2 Overview
Section B Product Specifications Table of Contents
New Motor Series Product Specification Premium Efficiency Motor Series for North America: EP.NA Motor, 60Hz Motor Item Description Motor Type Enclosure Power Range Poles Standard Voltage Optional Voltage Duty Service Factor Inverter Duty Safety Certification Efficiency & Certification Protection Insulation Class Frame Material Conduit Box Bearings 3 Phase, Induction Motors, Squirrel Cage Totally Enclosed, Fan Cooled 1HP through 75HP 4 Poles 230/460V, 60Hz and 575V, 60Hz 240/480V, 60Hz Continuous 1.15 on Sinusoidal Power, 1.0 on Inverter Power Non-Brake: 10:1 CTSR Brake: 4:1 CTSR or better UL Recognized, CSA Approved, CE Mark Premium Efficiency & DOE CC305B, NRCAN IP55 (except IP54 for 20HP through 40HP, brakemotor) 155 Class F upto 20HP: diecast Aluminum above 20HP: cast Iron Type: Global Conduit Thread: NPT Material: upto 50HP: diecast Aluminum above 50HP: cast Iron Deep Groove, Ball Bearing, CM Clearance Section B Product Specifications B-1
New Motor Series Product Specification cont. Premium Efficiency Motor Series 50Hz Regions: IE3 CE Motor, 50Hz Item Description Section B Motor Type Enclosure Power Range Poles 3 Phase, Induction Motors, Squirrel Cage Totally Enclosed, Fan Cooled 0.75kW through 55kW 4 Poles Standard Voltage upto 3.7kW: 230/400V, 50Hz above 3.7kW: 400V, 50Hz Optional Voltage upto 3.7kW: 220/380V, 50Hz and 240/415V, 50Hz above 3.7kW: 380V, 50Hz and 415V, 50Hz Duty Continuous Service Factor 1.0 Inverter Duty Non-Brake: 5:1 CTSR (0.75kW thru 15kW); 10:1 CTSR (18.5kW thru 55kW) Brake: 3:1 CTSR or better Safety Certification CE Mark Efficiency IE3 (Premium Efficiency) Protection IP55 non-brake; IP44 brakemotor Insulation Class 155 Class F Frame Material upto 15kW: diecast Aluminum above 15kW: cast Iron Conduit Box Type: Global Conduit Thread: Metric Material: upto 50HP: diecast Aluminum above 50HP: cast Iron Bearings Deep Groove, Ball Bearing, CM Clearance B-2 Product Specifications
Special Voltage Motors US Requirements The EP.NA Motors will include on the nameplate rated amperage on Usable 208V Networks in addition to 230/460V, 60Hz rating. At 208V, the motor will not be rated for Premium Efficiency levels; however, the DOE does allow for voltage ranges and when there is a range, the regulated efficiency is determined by the efficiency at the highest voltage level in the range. If an end user wants a motor rated at 208/415V, 60Hz, Sumitomo will not be able to renameplate a 230/460V, 60Hz motor to the new rating since at 208/415V, 60Hz, the motor will not comply with DOE Premium Efficiency requirements. Voltage Action Section B 230/460V, 60Hz Standard, includes Usable 208V 240/480V, 60Hz 220/440V, 60Hz 208/415V, 60Hz 200/400V, 60Hz 190/380V, 60Hz Optional EP.NA offering, renameplate 230/460V, 60Hz stock motor Non-EP.NA, DOE certified, requires special stator Non-EP.NA, DOE certified, requires special stator Non-EP.NA, DOE certified, requires special stator Non-EP.NA, not DOE certified 50Hz Rated Only Motors Motors rated for 50Hz only are not covered by DOE regulation; however, Advanced Energy has indicated that these may need to be handled by Export only rule unless certification designation is included. Further investigation may be necessary. 60Hz Nameplate with 50Hz Information Currently, there are no plans to have the EP.NA Motor to include 50Hz rating information. The rationale for this is the added development and certification work involved for this approach. Further the nameplate real estate is already crowded. Another method for customers requiring dual 50/60Hz rating may be to include a re-rated nameplate at 50Hz shipped loose that the customer can apply later if the customer plans to ship the motor overseas. Product Specifications B-3
Other Regions as of 2015 Regions Efficiency Regulation Status Action Section B Canada Mexico Brazil Gearmotors are regulated at high efficiency levels. Gearmotors are not regulated Gearmotors are regulated at high efficiency When released, EP.NA Motor at rated voltage of 230/460V, 240/480V or 575V will be certified for Canada. Consult Factory. Export only rule may need to be applied since Brazil is 60Hz country. Product is available from SHI/SHIV but does not meet US DOE regulation. Europe Gearmotors are currently considered non-regulated CE mark required. 50Hz Renameplate Option. Korea Gearmotors are regulated at premium efficiency levels Consult Factory. Export only rule may need to be applied since Korea is 60Hz country. Product is available from SHI/SHIV but does not meet US DOE regulation. China Gearmotors are regulated at high efficiency Chinese certified motors required. Although 50Hz country, Export only rule may be required. Japan Gearmotors are regulated at premium efficiency levels but not covered if motor is incorporated into another equipment Australia/New Zealand Gearmotors are regulated at high efficiency Australian certified motors required. Although 50Hz country, Export only rule may be required. 6-Pole Motors The DOE requires 6-Pole gearmotor (above 1HP) to meet Premium Efficiency requirement. Due to a number of factors including low sales, the first release of the Premium Efficiency motor product will not include 6-Pole motors. Currently, there is no established schedule for the availability of 6-Pole gearmotors so customer requiring 6-Pole motors will need to transition to C-face motor. B-4 Product Specifications
Section C Application Consideration for Motor Replacement Table of Contents
Due to the new DOE ruling, new equipment that were once built using older motor series will need to be updated with the new motor series as the older motor series become unavailable. In many applications, the new premium efficiency motor will be a welcome addition, as it provides energy savings benefits, reducing overall cost of ownership and cooler running motor. However, there are a number of product differences between the new Premium Efficiency motor and earlier lower efficiency motor series. The new motor series will result in following differences compared to older series as follows: Performance Differences: See Section D Inertial Differences: See Section E Gearmotor Start/Stop Service Factor Differences: See Section F Dimensional and Weight Differences: See Please see each of these sections for detailed values of the change. Section C Load Sharing Application Review Rated RPM Differences In applications, where multiple motors are pushing the same load and load sharing balance is critical, replacing all motors may be required to ensure that load sharing is maintained. With the new series motor, having a lower slip (higher rated speed) results in higher rated speed. If motors with mismatched, rated speeds are forced to carry the same load, the motor with the higher rated speed will be burdened with more load burden. This can result in overload situations for the new motor. Additionally, even if all the motors are replaced, the new motor with the higher rated speed may be more sensitive to load sharing burden due to the low slip. Stopping Distance/Time Inertia Increase The new premium efficiency motors have a higher moment of inertia. For applications, using a mechanical brake to stop the load, the increase in motor inertia may extend the duration of motion for the same braking torque. If this approach is being used to position the load to a given position, the increase inertia may cause an overshoot to occur. To correct for this it may be necessary to increase the brake torque or adjust the trigger point of the stopping function (usually a limit switch) to a position that triggers the stop earlier. Brake Maintenance Impact Inertia Increase The increase in motor inertia will correspondingly increase the energy absorbed by the brake if the brake is used primarily to stop the load. The mechanical brake stops the load by absorbing the kinetic energy of the system. Since the kinetic energy is proportional to the inertia of the system, any increase in inertia will increase the kinetic energy of the system. If the brake is absorbing this increase in kinetic energy, you should expect the brake lining to wear faster, thereby requiring more frequent maintenance cycle to adjust brake gap and replace brake lining. Application Consideration for Motor Replacement C-1
VFD Setup Adjustment Nameplate Information and Performance Change Section C If the new premium efficiency motor is used to replace and existing motor operated by a VFD, the VFD parameters may need to be re-adjusted. - Thermal Electronic Setting: Set to Nameplate FLA - Thermal Characteristic: 10:1 speed range, non-brake, consult factory for brakemotor - Advanced Control (i.e. Sensorless Vector Control): Set NLA, Rated RPM (See Rating Tables) High Frequency Start-Stop Cycling Application Inertia / Starting Current In applications that have frequent starts and stops, special consideration may need to be made when converting from an older series to a newer series motor. The high frequency start-stop cycling application can be categorized into two basic classes: 1) across-the-line and 2) VFD operated. In high frequency start-stop cycling application done across-the-line, several constraints need to be reviewed Motor thermal capacity: No Change (increased starting current and increased motor inertia increases motor losses, but this is counted by larger motor thermal capacity and higher efficiency at operating speed) Higher Inrush: The new series motors have higher starting current. Previously motor may have been NEMA Design B, but the new motors may have changed to NEMA Design A. The higher starting current may require changes to fuses, breakers and service mains. An alternate to change in service mains may be the use of soft-starters or VFDs to lessen the peak current capacity of the new motor series. Speed Reducer Shock Capacity: Speed Reducer recommended Service Factor for high frequency start-stop capacity has been adjusted to handle higher starting torque generated by the new series motor is advisable. Please see Section F on supplementary service factor for high frequency start-stop applications. Stopping Time Review: The higher motor inertia may extend stopping time if brake is used to stop the load. If extended braking time is problematic to the start/stop cycle, increasing the braking torque may be necessary. In high frequency start-stop cycling applications involving a VFD, the higher inertia will typically increase the acceleration and deceleration torque of the system. Adjustments to the VFD acceleration time and VFD deceleration time may be necessary to limit the current capacity. Alternatively, allowing higher peak current and/or DB resistor capacity may be required if adjustment to the move profile is restricted by the application needs. C-2 Application Consideration for Motor Replacement
Section D Performance Differences Table of Contents
Performance Differences To achieve the required efficiency levels to meet the new ruling, the new motor series has performance differences compared to older motor series. The new motor series, EP.NA, is compared against standard motor series and CSA approved motor series at 460V and 575V. For 230V comparison, the amperage (NLA, FLA and LRA) will double when compared to 460V values. Please verify the motor frame when using comparision tables below. For other voltages or motor frames, please consult factory. Table D.1 Performance Comparison: Standard (IE1) vs EP.NA (IE3) at 460V Section D Table D.2 Performance Comparison: CSA Approved (IE2 except 1HP/IE1) vs EP.NA (IE3) at 460V Table D.3 - Performance Comparison: CSA Approved (IE2 except 1HP/IE1) vs EP.NA (IE3) at 575V Performance Differences D-1
Section E Inertial Differences Table of Contents
Inertial Differences The new motor series EP.NA and CE IE3 Motors have generally higher motor inertia when compared with the older motor series. This higher inertia results in more power requirements during acceleration and longer coasting time or deceleration time when stopping. See tables below for inertial values of new and older motor series. Table E.1 Inertial Values for Different Motor Series: Inertia (WR 2 ) in units of lb-in 2 (kg-m 2 ) Section E Inertial Differences E-1
Section F Gearmotor Start/Stop Service Factor Differences Table of Contents
Gearmotor Start/Stop Service Factor Differences Another change that has been implemented is the recommended start/stop service factors for gearmotor selection that are found in some catalogs. These service factors are used to select the gearbox side selection to accommodate application requirements based on high cycling start/stop and load inertia levels. With the new IE3 motor, the higher starting torque when operating across-the-line raise concerns of increased shock load. As a consequence, the service factor levels have adjusted the service factor range and service factor levels. Verify gearmotor service factor in respective gearmotor catalog against Recommended SF. Table F.1 Recommended Start/Stop Service Factor for Standard Efficiency Motor Section F Load Classification from Inertia Ratio I : Inertia Ratio 0.3 II : Inertia Ratio 3 III : Inertia Ratio 10 where Inertia Ratio = Load Inertia (incl. Reducer) at Motor Shaft Motor Inertia Gearmotor Start/Stop Service Factor Differences F-1
Table F.2 Recommended Start/Stop Service Factor for Premium Efficiency Motor Section F F-2 Gearmotor Start/Stop Service Factor Differences
General Dimensional and Weight Differences Table of Contents
General Dimensional and Weight Differences The following information is provided to help identify changes to dimensions and weights of the new motor product when compared with the older motor series. Steps: 1. Identify Older Motor Series 2. Identify Input Flange 3. Identify Dimensional and Weight Increase 4. Identify Clearance Requirements with New Motor MP AB C Step 1 - Identify Older Motor Series Standard Motor Series This is the most common motor series that was available globally. This motor series has many variations and standard motor series sold in the United States is used as reference for comparison. The standard series sold in the United States has Global Conduit Box, but there are other types of conduit boxes which result in differences in AB dimension only. AF-Motor Series Inverter Duty Motor Series identified by Suffix AV in the gearmotor nomenclature. The motor frame designations for these motors are sometimes different from the standard motor series, resulting in differing dimensions and weight comparatively. CSA Motor Series Motor series with CSA approval (Canada) is typically comprised of high efficiency motors above 1HP. The high efficiency motors are typically larger, resulting in different motor frame designation. CSA AF-Motor Series Inverter Duty Motor series with CSA approval (Canada) generally match the CSA Motor Series in terms of dimensions and weights. However, a few motor power sizes have differences so the entire series is presented for comparison. Table G.1 Motor Frame Size for Older Motor Series If the motor series currently being used is in doubt, you can try to find the best matching power/framesize to determine which table to use. If there is no matching combination, the best selection may be to find a matching framesize. The Table G.1 to the right shows the standard motor framesize for each motor series and power. Please consult factory if motor frame is not found or special conditions apply. Please note that these values may be subject to change without notice. General Dimensional and Weight Differences G-1
Step 2 Identify the Motor Flange The motor length and weight will change depending on the motor flange. For a given motor power, there may be different motor flanges to match-up with the reducer framesize. Please see tables below to identify the appropriate motor flange. Four gearmotor products are shown. Please consult factory for other reducer product lines like Rhytax, Prest and Altax. Table G.2 Cyclo Single Reduction Frames Table G.3 Cyclo Double Reduction Frames Table G.4 Hyponic Frames Notes: # in framesize indicates character of type 0 or 5 or H. x in framesize indicates BBB4 or BBB5 casing size (i.e. Z, A, B, C, D, E, F ) Step 3 Identify the Dimensional and Weight Increase After determining the motor flange and motor series, select the appropriate dimensional table from the chart below to identify the increase in AB, MP and C as well as the increase in motor weight. Motor Series Configuration Standard AF-Motor CSA CSA AF-Motor Non-Brake Table G.6 Table G.8 Table G.10 Table G.12 Brake Table G.7 Table G.9 Table G.11 Table G.13 When identifying the dimensional data, verify that the motor frame matches with the one in the table. G-2 General Dimensional and Weight Differences
Step 4 Clearance Requirements with New Motor With the new motor, we have recommended clearance between back of the motor and any barriers that restricts airflow and removability of the fan cover for brake maintenance. FA Clearance: Remove Fan or Brake FB Clearance: Proper Ventilation Table G.5 Motor Clearance Requirements units: inch (mm) General Dimensional and Weight Differences G-3
Table G.6 - Weight and Dimensional Change: Standard Series to EP.NA Series, No Brake G-4 General Dimensional and Weight Differences General Dimensional and Weight Differences G-5
Table G.7 - Weight and Dimensional Change: Standard Series to EP.NA Series, Brake G-6 General Dimensional and Weight Differences General Dimensional and Weight Differences G-7
Table G.8 - Weight and Dimensional Change: AF-Motor Series to EP.NA Series, No Brake G-8 General Dimensional and Weight Differences General Dimensional and Weight Differences G-9
Table G.9 - Weight and Dimensional Change: AF-Motor Series to EP.NA Series, Brake G-10 General Dimensional and Weight Differences General Dimensional and Weight Differences G-11
Table G.10 - Weight and Dimensional Change: CSA Series to EP.NA Series, No Brake G-12 General Dimensional and Weight Differences General Dimensional and Weight Differences G-13
Table G.11 - Weight and Dimensional Change: CSA Series to EP.NA Series, Brake G-14 General Dimensional and Weight Differences General Dimensional and Weight Differences G-15
Table G.12 - Weight and Dimensional Change: CSA AF-Motor Series to EP.NA Series, No Brake G-16 General Dimensional and Weight Differences General Dimensional and Weight Differences G-17
Table G.13 - Weight and Dimensional Change: CSA AF-Motor Series to EP.NA Series, Brake G-18 General Dimensional and Weight Differences General Dimensional and Weight Differences G-19
Table G.13 - Weight and Dimensional Change: CSA AF-Motor Series to EP.NA Series, Brake G-20 General Dimensional and Weight Differences General Dimensional and Weight Differences G-21