(Wi Inverter_Energy_Seving_ENG Inverter Energy Saving Course This course will help you understand how inverters enable energy saving operation Copyright ©2 Mitsubishi Electric Corporation. All Rights Reserved uwajoo198encA Iowerter_Energy_Saving_ENG el as [introduction | Purpose of the course ) soc Through the lessons in this course you will learn + Why en inverter driven motor can save energy + How high-efficiency motors enable further energy saving This course requites a basic knowledge of inverters. Itis recommended that you start with the beginners course, “FA Equipment for Beginners (Inverters)(@ Inerter_Energy_Seving_ENG oa = Course structure > eeo The contents of this course are as follows. Chapter 1 - Trends Lear about the trends in energy saving. Energy Saving Chapter 2 - Principle of Energy Saving with Inverters Leam about the principle of energy saving to understand why inverters are used for this purpose Chapter 3 - Useful Energy-Saving Functions in the FR-F800/700 Series Leam about the useful energy-saving functions available in the FR-F800/700 series. Chapter 4 - High-Efficiency Motor Regulations Leam about the regulations on high-efficiency motors Chapter 5 - Superline Premium Series SF-PR Leam about the Superiine premium series SF-PR Chapter 6 - Energy Saving with Inverters and IPM Motors Leam about energy saving with the combined use of inverters and IPM motors. Final Test Pass grade: 60% or higher(Wi Inverter_Energy_Seving_ENG eee ed rae a earning to! Go to the next page. Back to the previous page. “Table of Contents" will be displayed, enabling you to navigate to the desired page. Exit the learning.A Iowerter_Energy_Saving_ENG els [introduction | Cautions for use ) aaa Safety precautions When you learn based on using actual products, please carefully read the safety precautions in the corresponding manuals. Precautions in this course The displayed screens of the MELSOFT engineering software that you use may differ from those in this course.(Wi Inverter_Energy_Seving_ENG ae) Cam Trends in Energy Saving This chapter explains the trends in energy saving and the percentage of motor energy use in the world's energy consumption, 41.1 Trends in Energy Saving 1.2 Percentage of Motor Energy Use in World Energy Consumption 1.3 Summary ) socA Iowerter_Energy_Saving_ENG os Trends in Energy Savin goo Europe | + 2001 Directive on the promotion of electricity produced from renewable energy sources in the | internat electricity market was established. | Renewable energy targets by country were defined | + 2009 Directive on the promotion of the use of energy from renewable sources was established. | This directive sets targets for all EU countries with the overall aim of making renewable energy sources | around 20% of the EU's energy consumption by 2020. | i France | + 2005 Energy Act was established. | This act defines the following targets: | + 4.75% reduction in greenhouse gases by 2050, | + Improvement of the energy efficiency by at least 2% per year on average by 2015 and 2.5% per year on average between 2015 and 2030. musa + 2011 The state law entitled Renewable Portfolio Standards (RPS) was introduced. Thirty states and territories have adopted the RPS to promote the use of energy from renewable sources. ‘The goal is 23% of electricity retail sales be served by renewable energy sources. China + 2006 Renewable Energy Law was established. ‘The goal is 15% of the total energy use to be served by renewable eneray sources by 2020. + 2011 The 12th Five-Year Plan (FYP) was estal The targets of this plan include + A17% reduction in CO, emissions by 2015, + Incteasing non-fossil energy to 11.4% of the total energy use. ed.(Wi Inverter_Energy_Seving_ENG Percentage of Motor Energy Use in World Energy Consumption coc Motors are used everywhere in our daily life. For example, motors are used for: ‘Shares of World Energy Consumption (21.4 trillian KWh in 2070). + Airconditioning equipment tlecvat qugmen Ot (for buildings, shopping centers, factories, etc) itsewers + Elevators/escalators Elettea! spline + Machine tools + Conveyors Uectealheeing cecuiprent heaters) Etec hetingfrna Hectic boils ete Multi-story car parks Since motors are used for many different types of equipment, the energy consumed by electric motor systems accounts for 46% of the world's energy consummation {About 55% in Japan) Ifall the motors currently being used were replaced with energy-saving motors, the energy consumption would be far lower than itis today. ‘Source: MOTOR SUMIVIT 2012 - Key Worle Eneray STATISTICS 2012 Shares of Japan's Eneray Consumption (1 trillion kWh in 2009) sO ox O% om 0% B ‘Source: VAE-0919107 (2005 Survey report on the actual situation of eneray-consuming ecuipment)(Wi Inverter_Energy_Seving_ENG ae) Gl Summary ) soc In this chapter, you have learned: Points pone ee ted Sein Moneta “There are growing concerns about environmental problems due to the increase in the average temperature around the globe, such as abnormal climate change, {decline in crop productivity, impact on ecosystems, and habitat change resulting {rom rising sea levels. Prompt energy-saving action is urgently needed to prevent global warming (to reduce CO; emissions) ‘Since motors are used for many diferent types of equipment the energy consumed by electric motor systems accounts for 46% ofthe world's energy consumption. If all the motors curently being used were eplaced with energy-saving rotors, the energy consumption would be far lower than itis today.(Wi Inverter_Energy_Seving_ENG Gz Principle of Energy Saving with Inverters This chapter explains the principle of energy saving with inverters. 2.1 How to Change Speed with Standard Motors 2.2 Driving Standard Motors with Inverters 23 Lead Torque Characteristics 2.4 Concept of Energy Saving Calculation 25 SummaryA Iowerter_Energy_Saving_ENG ae) Gill How to Change Speed with Standard Motors ) soc ‘The air volume is controlled with a shielding plate called a damper. Since the motor speed is constant, decreasing the air volume does not greatly reduce the energy consumption Generally, the speed of a standard motor cannot be changed. The motor speed usually changes by means of a coupling, which is installed between the motor and the load to create a sliding effect. For a variable-torque load, dampers or valves are normalty used to reduce the air or water flows However, since the rotation speed of a standard motor is almost constant, the motor output does not change much even when the load speed or air/water volume changes, Therefore, the remaining power after subtracting ‘the required power from the motor output is consumed as heat loss at the coupling or damper.(Wi Inverter_Energy_Seving_ENG Dri ing Standard Motors with Inverters The air volume is controlled by the motor speed, which can be reduced by lowering the ‘output frequency. Reducing the air volume will lead to large eneray savings mm 30H: lm Why can inverter-driven motors save energy? When a motor is driven by an inverter at a medium speed, the voltage is reduced in proportion to the motor speed regardless of the current flow. This contributes to energy saving. It can be said that in any application, driving a variable-speed motor with an inverter can reduce the energy consumption, This means that driving a variable-speed motor with an inverter can save far mare energy than driving a standard motar with 2 commercial power supply and applying brakes to reduce its speed to a medium speed, [Blower Operation Characteri wf tacecaly 2 z Driven by commercial © sco} powerscply 2 0 E 5 6 8 4 S 2» So oa 6a) 100 Air volurne (9) Output voltage Base frequency voltage Base Output frequency frequency(Wi Inverter_Energy_Seving_ENG Load Torque Characteristics Constant-torque load: The torque does not change much even if the motor speed changes. Main applications: Conveyors, carriers, etc. 3 output { 5 i 5 & Toraue 6 Frequency (Rotation speed) lm Constant-output load: As the rotation speed increases, the torque becomes smaller. Main applications: Machine tools, winders, etc. & Output 5 5 Torque Frequency (Rotation speed)Load Torque Characteri: Ml Variable-torque load: As the rotation speed decreases, the torque becomes smaller. Output fi 2 Torque Large energy savings can be é expected when a machine with a 3 variable-torque load is controlled £ using an inverter, compared to when 6 itis controlled using a commercial power supply. Frequency (Rotation speed) ————— Main applications: Fans, pumps, blowers, etc.(Wi Inverter_Energy_Seving_ENG os Load Torque Characteristics soc Load torque: Proportional to the square of the rotation speed (air volume) T >= Ne ‘xis output: Proportional to the cube of the rotation speed (air volume) P= NF Specifically, as shown in the following graphs, when the rotation speed is reduced to 50%, the motor axis power decreases 10 cays = 78 ‘Axis output (9) Load torque (%) Rotation speed (air volume) (%) Rotation speed (air volume) (%4)A Iowerter_Energy_Saving_ENG el as ell Concept of Energy Saving Calculation ) ooc Total energy and electricity charges to be saved per year can be calculated by obtaining the difference in annual energy consumption between a motor driven by a commercial power supply and a motor driven by an inverter. For details about the calculation method, refer to TECHNICAL NOTE No. 27 ENERGY SAVING CALCULATION USING INVERTERS.(Wi Inverter_Energy_Seving_ENG ae) eal Summary ) soc In this chapter, you have learned: Points Pe aes ee enone te ore “The aie volume ie controled with a shielding plate called a damper. Since the motor speed is constant, decreasing the air volume does not greatly reduce the ‘energy consumption, “The air volume is controlled by the motor speed, which can be reduced by lowering the output frequency. Reducing the air volume will lead to large energy savings. Large energy savings can be expected when an inverter controls a machine with a varible-torque load (eg, fan, pump, or blower), asthe axis output is reduced to 118 compared to when itis operated using a commercial power supply. itis important to calculate the total energy and electricity charges to be saved per yearby obtaining the difference in annual energy consumption between a motor riven by a commercial power supply and a motor driven by an inverter.A Iowerter_Energy_Saving_ENG el as [ chapter3 | Useful Energy-Saving Functions in the FR-F800/700 Series ) soc This chapter explains the FR-F800 and FR-F700PI series, and their functions that contribute to saving energy. 3.1 Introduction of FR-F800 and FR-F7O0P) Series 3.2 Enhanced Energy-Saving Operation 3.3 Compatibility with Motors of Other Manufacturers 3.4 Standby Power Reduction 3.5 Energy Saving at a Glance 3.6 Summary In this chapter, the following icons are used to indicate the series in which the function is available leon Corresponding Inverter FR-F800 =m (700TH | FR-F700P)(Wi Inverter_Energy_Seving_ENG Introduction of FI ‘800 and FR-F7OOPJ Set IN FR-F800 Series — Next-generation Inverters with Enhanced Energy-Saving Control The FR-FBOO series inverters are easy and safe to use, and support a wide range of energy-saving applications, offering a variety of functions ideal for fans and pumps The FR-FBOO series offers next-generation energy-saving inverters ideal for fans and pumps. + Anewly developed advanced optimum excitation control delivers a large starting torque while maintaining the same motor efficiency as under the conventional optimum excitation control + Both standard motors and IPM motors are supported. IPM motors achieve even higher energy efficiency than standard motors. The motor to be used can be switched between @ standard motor and an IPM motor by only assingle setting + The tuning function enables the inverter to support both general-purpose and PM motors of ‘other manufacturers(*), which increases the range of inverter applications for energy saving + With the 24 VOC external power supply, the input MC signal can be turned OFF after the motor is stopped, and turned ON before the motor is activated The inverter enables self power management to reduce standby power. “1: Depending on the characteristics of the motor to be used, tuning may not be feasible S IN FR-F70OPJ Series - Compact Inverters Suitable for Air Conditioning Systems Functions ideal for fans and pumps enable energy saving, The built-in filter pack achieves ¢ compact design with reduced wiring, + The adopted rotation speed control for controlling the air volume saves energy. + The energy saving efficiency can be easly checked on the energy-saving monitor or vith the square wave of the output power: + Both standard motors and IPM motors are supported. IPM motors achieve even higher energy efficiency than standard motors. The motor to be used can be switched between a standard motor and an IPM motor by only a single settingId trverter_Energy_Seving_ENG tl Gal Enhanced Energy-Sa' in | e00 > seo Anewiy developed Advanced optimum excitation control delivers a large starting torque while maintaining the same motor efficiency as under the conventional Optimum excitation control, Rapid acceleration is enabled without troublesome parameter settings (e.g. torque boost, acceleration/deceleration time). Energy-saving operation with ‘maximum motor efficiency is possible during operation at a constent speed ig Opera’ 2 3 oO «BS «NOD Comporedto, | Motor load factor (1) urceneentora)) “roitgiretewariwecc BY! iy(Wi Inverter_Energy_Seving_ENG eo Compat h Motors of Other Manufacturers The offiine auto tuning function to measure circuit constants of the motor enables optimal operation of motors even when motor constants vary, when 2 motor of other manufacture's is used, or when the wiring distance is long. AS well as Mitsubishi general-purpose motors, Mitsubishi PM motors (MM-EFS, MM-THE4), sensorless operation can be performed for other manufecturers' general-purpose motors* and other manufacturers’ permanent magnet (PM) motors’ The tuning function enables the Advanced optimum excitation control of other manufacturers’ general-purpose motorst, which increases the use in the energy saving applications. *: Depending on the characteristics of the motor to be used, tuning may not be available. Mitsubishi general purpose (induction) motor SF-PR (e PM motor by other manufacturers Mitsubishi 1PM motor Generek-purpese motor HME by ether manufacturers(Wi Inverter_Energy_Seving_ENG Standby Power Reduc! In addition to the control power supply to R1 and $1 (AC), 24 VDC ower enabling sfemaintenance work aggu turned ON before the motor is activated, Since signals can be output in response to the operation of the input is also equipped Since the 24 VDC external power supply allows the control circuit to operate independently, parameter setting and ‘communication are possible even after turning off the main power. This contributes to the reduction of standby J | g24 VDC power supply + With the 24 VDC external power supply, the input MC signal can be turned OFF after the motor is stopped, and The inverter enables elf power management 10 reeuce sardby power SOB + The inverter cooling fan can be controlled in response to changes in the temperature of the inverter cooling fins. inverter cooling fan, a fan installed on a panel can be operated in synchronization with the inverter cooling fan. Unnecessary energy consumption while the motor is(Wi Inverter_Energy_Seving_ENG + Energy saving monitor is available, The energy saving effect can be checked using an operation panel, cutput terminal, or network, + The output power amount measured by the inverter can be output in pulses. The curnulative power amount can bbe easily checked + With the Mitsubishi energy measuring module, the energy saving effect can be displayed, measured, and collected.(Wi Inverter_Energy_Seving_ENG ae) In this chapter, you have learned: Points Energy-Sovi mpatibilty with Motors of Other Renata’ Saad Gall Summary ) soc ‘oth standard and IPM motors are supported. ‘large stating torque can be delivered while maintaining the same motor fancy as under the conventional optimum excitation contra The auto-tuning function for automaticaly calculating the motor constant promises motor operation withthe optimum characteristics even when there is discrepancy in the motor constants the motor is from another manufacturer, oF the installed wiring is long. ‘R24 VDC external power supply allows the contol circuit to operate independently, which reduces the standby power The energy saving monitor is avallable and the output power amount can be ‘output in pulses. ‘The energy saving effect can be checked.(Wi Inverter_Energy_Seving_ENG Cx High-Efficiency Motor Regulations This chapter explains the regulations related to high-efficiency motors 4.1 About High-Efficiency Motor Regulations 4.2. What is IE? 43 World's High-Efficiency Motor Regulations 4 4.4 Summary(Wi Inverter_Energy_Seving_ENG 4 ‘About H ‘fficiency Motor Regulations sos Large energy savings can be achieved by improving the efficiency of motors, or by using motors combined with inverters, As its estimated that nearly 60% of the world’s electric power is consumed by motors, the effect of such improvernent can lead to large energy savings. The introduction of regulations for mandatory use of high-efficiency motors is being promoted worldwide due to the increasing awareness of the need for energy saving to prevent global warming. fa new motor mony indus but not you. applications,(Wi Inverter_Energy_Seving_ENG ob = € EE whatis ) soc IE is the abbreviation for Intemational Efficiency Standard Level and it defines the international standards for motor efficiency. The global trend towards improving etficiency is accompanied by rising demand for high-efficiency ‘motors, To increase the use of high-efficiency motors worldwide, it was necessary to integrate the motor efficiency standards that had been uniquely defined according to individual countries. In October 2008, the IEC established the international standard IEC 60034-30 (Efficiency classes for single-speed squirrel-cage induction motors). This standard defines the IE codes. The IE codes include four classes. Te (euper premium cfceney) 1E3 (eremium eftelency) TED igh effceney) Below the ess +2 The detail fae defined in IEC 6002431 standards, but their application ‘Now, let's check th regulations in oth(Wi Inverter_Energy_Seving_ENG World's High-Efficiency Motor Regulations soc steps CSUs BiB esrope Ines eos sig Pos ms he fe othe ee eos e120. hon man gv erhos toes seed pte ie ay mera ne nace repens poe hee ey Seromone comet etesbarjwaey, od meer cnr pace nsepechconomen sre sre eerie 0m Soca rorsarwrpensboe 89 shen ongeho neoepe kyon wahoo neater cash he Sse epten tl ony 101 ping beefs 8 a eet cen eng Fy 20 mero s shoo mst eel art Ore eter ese own ‘must meet the Grade GB2 (equivalent 10 £3) eficency level, Starting on Janey 1, 2017, motors from 0.75 10375 kW must meet the GB2 (3) efficiency level Our SF-PR-CN motors are applicable.A Iowerter_Energy_Saving_ENG ae) Gall World's High-Efficiency Motor Regulations ) soc Korea 2 regulation vas introduced in July 2008 requiring an atficency level equivalent to IE2. The enganzations for which certification ie mandatory are limited to cemparies that have their factories in Korea. The regulation was updated on January 1, 2015, stipulating that motors must meet the IE3 efficiency level The power range ofthe motors to which the regulation applies will be extended in stages. Our SF-PR-KR motors are apoicable, U.S.A. Motors were originally regulated by the EPAct to provide for improved energy efficiency equivalent to IE2. EPAct was followed by the Energy Incepandence ard Security Act ESA", whieh care into eect in Decomber 2010, The major amendments areas follews: ‘¢ Motors must meet the efficiency level equivalent 1oIE3 instead of the previously applied IE lvel ‘= The regulation has been extended to make the E2 level mandatory for motors that were previously cutside the scope of the EPAct. Our SF-PR motors are applicable WS [eanaaa Since January 2011, higher enorgy efficiency has been pursued within the range of regulations that follow those enforced in the USA. Fev The revised energy efficiency regulation came into force in January 2011, Basically, North and Central America have vied to achieve high etfxiency levels within the range of raguations that follow those enforced in the U.S.A, Homever, when exporting motors, attention must be paid to ‘encoptions that may be included in re ragulations. Our SF-PR-MX motor: are applicable, ens Being a member ofthe BRICS group, Brazil ranks Bthn the word in primary energy consumption. AS of December 8, 2008, motoes must be certifies as almost the same eneray effconcy class as required by EPAct fie, equivalent to E2), In addition labeling is mandatory forthe certifi products @ Jepan Further improvement of high energy efficiency of the motors themselves has been under discussion since November 2009, In 2912, he ceria were announced for evaluating energy efficiency based on the Energy Conservation Lave and the Law concerning the Rational Use of Energy (Grergy Conservation Law) was enacted in April 2015. Asa result, motors to be supplied must meet the Tep Runner standard in principle. Our SF- PR mocors are applicable,(Wi Inverter_Energy_Seving_ENG ae) cl Summary ) soc In this chapter, you have learned: Points Se een or re cond Regulations Introduction of regulations for mandatory ute of high efficiency motors is being promoted globally I is the abbreviation for Intemational Efficiency Standard Level and it defines the international standards for motor efficiency. {In October 2008, the IEC established the international standard 1€C 60024-30 (Efficiency classes of singlespeed, cage-induction motors), n which the Ie codes are defined. ‘An increasing number of countries throughout the world have been introducing ‘egulations on high-elfiency motors; however, Japan lags sighily behind Europe and the US. in terms of etforts to introduce such regulations.A Iowerter_Energy_Saving_ENG 2 = Superline Premium Series SF-PR > asG This chapter explains the superline premium series SF-PR compatible with IE3 premium efficiency. When used in combination with the FR-A800 inverter, the motor continuously operates from a low speed 5.1 Comparison of Energy-Saving Efficiency between the SF-PR and the SF-IR 5.2 SF-PR Motor Best Suits the FR-F80O Series 5.3 Estimation of SF-PR Motor Energy-Saving Effect 5.4 Simulation on SF-PR Motor Life-Cycle Cost (LCC) 5.5 SF-PR Motor Lineup 5,6 Summary(Wi Inverter_Energy_Seving_ENG os Annual savings (electricity charges) ‘with 2 6% increase in efficiency Approx. 75,000 yen/year in electricity charges can be saved. ‘Approx. 7.5 milion yen con "Se'saved per yeu, Comparison of Energ ‘The SF-PR motor conforming to Japan's unique Top Runner Program Standards (equivalent to IE3) achieves 6% higher energy efficiency than the SF-IR standard motor. (7.5 KW) Energy-saving operation can reduce electricity charges, reducing running costs. i | [O10 Niner tose D889! cacy wx {weer ~ emmyee ) MEET he ite be ae ene | 198 x( ee) rues \ez % idan % diy Mc, i 4 ca ro75ivn ( ‘om ) zs x(-essm - am )x tx ox ge x a moron * ies * ds * yey ica re = 75.06 yen faving Efficiency between the SF-PR and the SFR) @OG Exper (preduets + electety enarges) Years in use > il Calculate in Japanese yenA Iowerter_Energy_Saving_ENG el as [ SF-PR Motor Best Suits the FR-F800 Series coc If you want to drive an SF-PR motor by an FR-F800 inverter, all you have to do is set the SF-PR motor parameters (70, 73, 74) in Pr-71 Applied motor. Since the motor constants have been internally set to the FR-F80O inverters, no complicated settings are required. In addition to the conventional high-efficiency energy-saving motors, it can also be Used as an altemative to an inverter-driven constant-torque motor Ideal, high-efficiency motor Since the motor constants have been internally set to the FR-FB0O inverters, energy-saving operation is possible by simply setting the parameters. The SF-PR motor, which adheres to Japan's unique Top Runner Program Standards (equivalent to IE3), allows energy-efficient operation and reduced electricity charges, thus reducing running costs Efficiency (%) 100 4P 200V 50Hz 95 90 85 80 73 70 0.7515 223.7 5.5 7.5 11 15 185 22 30 37 45 55 Output (kW)(Wi Inverter_Energy_Seving_ENG [53 | Estimation of SF-PR Motor Energy-Saving Effect ) soc Energy-saving effect in our design building (inverter + general-purpose motor (SF-IR) +r Inverter + general-purpose motor (SF-PR) “The effect of replacing conventional Conditions Operation patterns system with invertor driven SF-PR motors [Units to ove} ‘@Annual energy-saving effect @vortitor Bowen) (differences in the amount and cost) O75 kW « 3 uit. ‘Approx. 17200 Wh 15RW x ton 240,000 yen Approx. 240, 22 kw = 3 unite Per yet @econaiioner 1S «unit Sasneweynr (@ Annual reduction in COv emissions tosh ctuse Jewinsémmater e wiinse-m moter] pppox izccowmn 9.5 ton Sohne Kypoe smh Roe ee Moet saamian’ — Abaesamaney vn ee Calculated in Japanese yen.(Wi Inverter_Energy_Seving_ENG ob = Gl Simulation on SF-PR Motor Life-Cycle Cost (LCC) ) ooc Usage conditions Motor capacity: 15 kW, Air volume: 70%; Hours of operation: 16 hours/day x 250 days/year = 4,000 hours/year Remarks The initial cost ofthe damper contra! (0 The bearing grease sence life has been extended, Since the rotor seldom generates heat, the bearing temperature s kept low. This extents the service life ofthe bearing grease "The servic fe ofthe motor bearings i largely ffectec by termporatue. itis estimated that 2 temperature drop of 10°C doubles the server lite ‘Motor capacity jew is the same as the standard price of @ Standard motor. Inverter model name Not used rr-re40.15x | The intial cost of introducing an inverter-crven standard motor or an inverter-criven PM moter includes the standard price ofthe motor to be Init cost 291,000 yen 1396800yer | introduced and its instalation cost (motor + inverter «05. Air volume (8) 70% ‘Annual elecicity consumption ay 64.200 kWh 29.400 kwh ‘Annual elecicity charges 907,200 yen 211,600 yen 14 yenrkwh ; The replacement cost varies Bearing replacement cost 120.000 yen 120.000 yen Temberertcot vat Bearing replacement cycle S years 5 years Inverter replacement cycle 10 years Difference in electricity charges 571,200 yen 75,600 yen The annual energy-saving eect after compared to PM “ar * introducing a premium IPM motor Difference in eduction of CO (1,000 kWh 5 0555 ton-COn ea reeeeiolaa 22.6100 29100 emissions) CC Gn 1,000 yer 14258 8153 LCC for 15 years Calculated in Japanese yen,(Wi Inverter_Energy_Seving_ENG Simulation on S! R Motor Usage conditions Motor capacity: 15 kW, Air volume: 70%; ife-Cycle Cost (LCC) Hours of operation: 16 hours/day x 250 days/year = 4,000 hours/year LCC {in 1,000 yen) Calculated in Japanese yen, vo oirriee moore enone See ears seo ee \ esa taeda |) A 12000 \ = \ 10000 x ——e a \ 8000 Replacement of ‘standard motor “ eo «on eae 4000 \standard motor bearings | wn eS wots ny nar cone ee ee a [compared to the standard motor driven by a commercial power supply ° 2 4 6 a 10 R 4 6 Operating period (years)(Wi Inverter_Energy_Seving_ENG SF-PR Motor Lineu, Compatibility in motor installation dimensions (frame number) between the SF-PR series and the SF-IR series makes it easy to replace a motor. Model name ‘SF -[PRI | : S| Superine svies Premise Natwest] row Netwed Wout be Delete pater cone 9 Sartome”_ Notuig "oun ype MS — Ne We a ae Fr Flange type ——_waterproof _ M Available range Number of poles o7s 15 22 a7 55 75, 17 15. ouput wn 2 = 7 45 3s(Wi Inverter_Energy_Seving_ENG ae) [56 | Summary ) soc In this chapter, you have learned: Points ee Pens enna ogee “The SF-PR motor conforming to Japan's unique Top Runner Program Standards (equivalent to IE3) achieves 6% higher energy efficiency than the SF- JR standard motor. (75 KW) Energy-saving operation can reduce electricity charges, reducing running costs. ‘Since the motor constants have been intemally set to the FR-F800 inverters, {energy-saving operation is possible by simply setting the parameters. The Sf 'PR motor, which adheres to Japan's unique Top Runner Program Standards {equivalent to IE3), allows energy-efficient operation and reduced electricity charges, thus reducing running costs. Replacing a standard motor (SFR) witha high-efficiency mator(SF-PR) reduces both electricity charges and CO, emissions. “The initial cost of introducing a high-efficiency motor (SF-PR) is expensive; however, its high efficiency and reduced power consumption wil realize more cost-effective operation aftr the fist two years compared to using a commercial power supply (damper contro. ‘Compatibility in motor installation dimensions (rame number) between the 'SF-PR series and the SF-IR series makes it easy to replace a motor.A Iowerter_Energy_Saving_ENG 2 = Energy Saving with Inverter and IPM Motor > asG This chapter explains energy saving with the combined use of an inverter and an IPM motor. 6.1 What is an IPM Motor? 6.2 Structure and Operating Principle of IPM Motors 6.3 IPM Motors (MM-EFS and MM-THE4) 64 Why are IPM Motors More Efficient than Induction Motors? 65 Comparison of Efficiency between IPM Motor Drive and Standard Motor Drive 6.6 Simulation on IPM Motor Life-Cycle Cast (LCC) 6.7 Estimation of IPM Motor Energy-Saving Effect 6.8 MM-EFS and MM-THE4 Lineup 6.9 Summary[@ Inverter_Energy_Seving_ENG oa = What is an IPM Moto! About IPM Motors IPM is the abbreviation for Interior Permanent Magnet IPM motors with permanent magnets embedded in the rotor have higher efficiency than induction motors, and meet the customers’ needs for further energy saving, IPM Motor Types of AC motors Synchronous =" Permanent motor magnetic system Surface permanent magnetic type: SPM (SPM: Surface Permanent Magnet) eee —_—_ Squirrel-cage type Coil type(Wi Inverter_Energy_Seving_ENG el as Structure and Opera’ Principle of IPM Motors soc IPM motor (synchronous motor) ‘General-purpose motor (induction motor) Primary stator Pri Primary stator Prima mary stator coil (core) stator coil (core) (three-phase (three-phase Structure call) shaft coil) (ection view) Permanent Secondary rotor! secondary rotor magnet ‘ (core) . ‘conductor *6-pole motor | (copper or aluminum “The suber of pols vaties depending on the motor capac. | “OPPS ? ‘The rotating magnetic field of the stator and the __| When power supply voltage is applied to the stator, Operating |™29"etc fields of the embedded magnets in the __| the rotating magnetic field appears, and a currents, wh i ty rotor generate the torque to produce rotation power. | induced in the rotor conductor. Torque is generated Princip between this current and the rotating magnetic field to produce the rotation power. fess Magnets are not used. Ceti ery Secondary an conductor ‘model Secondary rotor core Permanent . ; fanaa Stator Primary stator coil core(Wi Inverter_Energy_Seving_ENG ob = [ IPM Motors (MM-EFS and MM-THE4) goo 1 Compatible with the FR-F800/F700PJ series inverters Mitsubishi IPM motors (MM-EFS and MM-THE4) are compatible with the FR-F800 series and FR-F700P! series. Since the FR-F800 and FR-F7OOP) series support both IPM motors and standard motors, the first choice for improving energy efficiency is to introduce an inverter for operating @ standard 3-phase motor. After introducing the system, it can be improved in stages for higher energy efficiency, such as by replacing only the motor with an IPM. motor. = Common frame numbers (55 kW or lower) between premium high-efficiency IPM motors and induction ‘motors (4-pole) The motor can be replaced without making any modifications to the motar mounting frame of a machine designed for an induction motor. SFR STAN MMEFSS71M4(Wi Inverter_Energy_Seving_ENG Why are IPM Motors More Efficient than Induction Motors? Since no current flows through the rotor side (secondary side), there is no secondary copper loss. This reduces the energy loss. = The efficiency is improved. “Comparison of lossin motors, ‘Each of the following charts shows the breakdown of the motor internal loss. (Compared to our company’s products) General-purpose motor * For 22k Premium high- 400% efficiency IPM motor 1 vo 40% re co ‘ on :A Iowerter_Energy_Saving_ENG el as GGT ornparison of efficiency between IPM Motor Drive and Standard Motor Drive) @ OG Ifa standard motor (induction motor) is operated with an inverter at the same rotation speed as when it was operated using a commercial power supply, then the energy loss occurs only in the inverter. Meanwhile, when an IPM motor is operated with an inverter at the same speed as when it was operated using 2 commercial power supply, then the total energy loss in the IPM motor and the inverter becomes smaller than that when a standard motor is driven with a commercial power supply (55 KW or lower). Total efficiency (%) 6 POP PIS PPPS PPOL LAS Motor capacity (kW) (Compared to our conventional products) “ Efficiency: The IPM motor and the standard motor were operated with the inverter at the rated speed (1800 r/min); the total efficiency is the sum of the mator efficiency and the inverter efficiency under the rated load, In the combination of a standard motor and commercial power supply, the efficiency wes calculated while the motor was driven by the commercial power supply (220 V, 60 Hz)(Wi Inverter_Energy_Seving_ENG ob = Gaal Simulation on IPM Motor ‘Cycle Cost (LCC) ) ooc 1 Usage conditions Motor capacity: 15 kW; Air volume: 70%; Hours of operation: 16 hours/day x 250 days/year = 4,000 hours/year remats Water eapaiy 1507 The ill cot ofthe dame conrol Tavera model nae Noted 7000-15 ites 8 he stance of The il costo ited an inverter dive standard mtor oan invtercwen Motor ineses ial cost 231000 yen 132«800yen | 1738200yeq | Reterdven PM motor nce be toduced an ts nstaaton at notes Iered = 08 Airlume 6 70% fava eectitycomupton 4800 4m 2saoonwn |] 2ce0Kwn Annual lc cages 7 at0yen Tisooyen | 226000 en | ayer The eplocerent con varies Bearing replacement cost 120,000 yen 120,000 yen 130,000 yen ‘depending on the circumstances. Doorn replaced eye > Speer Syn Dyes Inet epacement cle Toye Toyears Ditferance in ect changer camo 7et0yen The anual vagy sing fect compared to IPM. 1200 yen uneiea ‘after introducing & premium IPM. Dilrarce neocon of De meter (oto kh 0588 on COD emissions (ton) compared to IPM atu ion emissions) LE 1.00 yen aa a Tan [eer sya (0) The bearing grease sonics life has been extended, ‘Since the rotor seldom generates heat the baring temperature s kop low. This extends the service life ofthe bearing crease "The serie fe ofthe mater beatings i largely afectec by temperature. Ie estimated thet 2 temperature drop of 19°C doubles the serie life ‘Caleulated in Japanese yer.(Wi Inverter_Energy_Seving_ENG 16000 4000 12000 10000 90 000 4000 Gall Simula' Usage condi LCC (in 1,000 yen) non IPM Motor Life-Cycle Cost (LCC) ) soc ions Motor capacity: 15 kW; Air volume: 70%; Hours of operation: 16 hours/day x 250 days/year = 4,000 hours/year CCaleulate in Japanese yen | —@— stancard marar driven ty commercial power supply (damper contra) [HI venerdrsentiohetieny moor |e — venerdrvenpremumrigh-erizeney PM mote Replacement of bearings of standard and IPM rotors* Replacement of inverter | Replacement of standard motor bearings Replacernent of inverter and standard motor bearings 2 4 6 ® 10 n 1 16 * The replacement cycle of the IPM motor bearings is 10 years, which is twice as long as that of the standard motor bearings Operating period (years)(Wi Inverter_Energy_Seving_ENG Estimation of IPM Motor Energy-Saving Effect Energy-saving effect in our design building (inverter + general-purpose motor (SF-IR) -+ Inverter + IPM motor (MM-EFS) The effects ofealacing Conditions Operation patterns conventional systerns with inverter ivan IPM motors Annual energy-saving fect [Units to cree] {diferencesin the amount and cost) {Srerietor iow) Approx. 32200 Wn O75 « 3 units O7SRW <2 ‘Approx. 420,000 yen: 22 Aunts (@hiconcioner ope mE 16k Lunt seston fesnw «tune (© van sence moto uth PM mot sak 2 unis spe ansmvin fypn00h w= | @Annuot reduction in C02 emissions Aprox 30.0080» 16,7 ton Calculated in Japanese yen Air conditioner for buildings (Inverter + general-purpose motor (SF-IR) ~ Inverter + IPM motor (MM-EFS) The effects of replacing Conditions Operation patterns conventional sysers with inverter ven IPM! motors ‘@Annual energy-saving effect [Units to oevel (differences in the amount and cost) (@ Fens far at corto 554 x tOunks ‘Approx 250.00 kh 1546 1Ounte Approx. 399 million 37 AW + 100 ants 2 sp | yen sttoto/ee ‘@Annual reduction in CO? emisions fragment @winimimate | type 200 158 ton Calealated in Japanese yen.(Wi Inverter_Energy_Seving_ENG els ee a eit cate coe sskwortowr MI M-EFS 71M es (GG ites and Mw-THes Lineup CSC mkwerkisher MI M-THE4 “The motor can be used for application which recuited the rated speed t 1500 r/min an 1209 erin. + For decicated motors such a the outdoor type long-ans ype. ange type. weteprcot and outdoor type nd the sl damage proof specication type, contact your sales tpretertathe, 5 . . m0 . ele Fa . . TWCaution + The IPM motor UM-EFS/MI-THEA sees cannot be driven by the commercial power supp {he total wiring lengU fo IPM motors should be 100 oes, + Only ove iPM mator can be connacted t each Ivor. + For abelt cre wih 2 MM EFS of IT KW or hohe, contact us Sc om =) Te fers 7s | Tsun] so | 20KW IM | 100d Netaed| POV Notun Stndoed— Notuied| Standard 1s f asia ie [aware [ a7 4 [—aov— | — Gass — Pi] 0utsoor Em EE EE ontario te ond nd of 1 ro ss[ ssiw] 2a | uw (© vate: “Not avaiatle(Wi Inverter_Energy_Seving_ENG MM-EFS and MM-THE4 Lineu, Premium high-efficiency IPM motor (3000 r/min) iskwortower MM -EFS S56 75 KW iru 15x [5 BW] WiCaution - Te IPM motor MM EF srs canot be operated nih commer! power sop ICaution °F total wing lngth for Pd motors shoal be 100 m less Cay one IPM motor can be connected to each verter -M motors with capaci of 11 KW or higher are dedicated for rect conneevon. (© vate: “Not avaiatle(Wi Inverter_Energy_Seving_ENG a Summary In this chapter, you have learned: Points renin a IPM Motors (MM-EFS and MM-THEA PROC) eee ny re ed IPM motors are synchronous motor with aroter in which permanent magnets are ‘embedded. IPM motors can provide higher performance and energy efficiency compared to induction motors. The rotating magnetic Feld of the stator and the magnetic elds of the embedded magnets in the rotor generate the torque to produce rotation power. ‘Mitsubishi IPM motors (MMM-EFS and MM-THE®) can be used for the FR-FB0O series ‘and FR-F70OP) series. The motor can be replaced without making any modifications to the motor mounting frame of a machine designed for an induction motor. Since no cutrent flows through the rotor side (secondary side), there is no secondary copper loss. This reduces the energy loss. ‘Meanuile, when an IPM motor is operated with an inverter at the same rotation speed as when it was operated with a commercial power supply the total loss of the IPM motor and the inverter becomes smaller than that when a standard motor is ‘operated with a commercial power supply (55 kW or lower. “The inital cost of introducing a premium high-efficiency IPM motor (MIM-EFS) is ‘expensive; however, its high efficiency and reduced power consumption wll eaize the most cost-effective operation after the fist five years. Replacing # standard motor (SF-IR) with an IPM motor (MM-EFS) reduces both electricity charges and CO, emissions, Explains the MM-EFS and MM-THE4 Tineup.A Iowerter_Energy_Saving_ENG els erm al Test ) soc Now thet you have completed all of the lessons in the Inverter Energy Saving course, you are ready to teke the final test. Ifyou are unclear on any of the topics covered, please take this opportunity to review those topics. ‘There are a total of 5 questions (20 items) in this Final Test. ‘You can take the final test as many times as you like. How to score the test After selecting the answer, make sure to click the Answer button. Your answer will be lost if you proceed without clicking the Answer button. (Regarded as unanswered question) Score results The number of correct answers, the number of questions, the percentage of correct answers, and the pass/fail result will appear on the score page. Correct answers: 5 To pass the test, you have to Total questions: 5 answer 60% of the questions correct. Percentage 100% Proceed Review + Click the Proceed button to exit the test. + Click the Review button to review the test. (Correct answer check) + Click the Retry button to retake the test again.(Wi Inverter_Energy_Seving_ENG els elect 4 ~-Select— sustore [Answer | | Test al Test 1 goo +): The torque does not change much even if the motor speed changes. te ea reases, the torque becomes smaller. Feaamn Rasonoe 17): As the rotation speed rene po 1|:As the rotation speed decreases, the torque becornes smaller BackA Iowerter_Energy_Saving_ENG ol >a Pea findtet2 ..»9ec © [onstant-torque load] ©. [Constant output load] Variable-torque load] Answer BackA Iowerter_Energy_Saving_ENG os Pe indtet3 2 eec © Annewly developed| Seleck~ 1 devers a large starting torque while maintaining the «ame motor efficiency as under the conventional optimum excitation conte © Both, Select = y) and Select + are support, and IPM motors achieve even higher anergy etfiiney ‘than stendard motors. The motor tobe used can he suited between a standard mator and an IPM mator by ony single seting. © The! ~Select- 1 function enables the inverter to support both general-purpose and PM motors of other manufactures which increases the range of inverter applications for energy saving. Select © wir tho 1) the input MC signal can be tumed OFF after the motoris stopped, and tumed ON before the motor is activated “The ivertr enables ~Salet {to reduce tandoy power «© enacay saving monitoris avaiable. The =Saket Jean be checked using an ‘operation pane, output termina, or network 1 The output power amount mensured by the inverter can be output in puin pues. he! Select can be easly checked (With the Mitsubishi energy measuring module) Select ¥) Answer Back(Wi Inverter_Energy_Seving_ENG ae) Test Final Test 4 ooc TE4 (super premium efficiency) 163 (premium efficiency) IE2 (high efficiency) TEL (standard efficiency) Below the class Answer Back SelectA Iowerter_Energy_Saving_ENG ela ee FinaltestS5 ~~» 8oc 100 95 90 85 80 Total efficiency (%) 75 70 PO Mand PnP PoP LE OPPO P OMS oY PAP DP gPP LI OPP P LMS ‘Answer Back Motor capacity (kW) [Compared to our conventional products][@ Inverter_Energy_Seving_ENG oa GRE rest s< ) Soc ‘You have completed the Final Test. You results area as follows. ‘To end the Final Test, proceed to the next page. Conectanevers 5 Total questions 5 Percentage 100% Ka aw Congratulations. You passed the test.(Wi Inverter_Energy_Seving_ENG You have now completed the Inverter Energy Saving course. Thank you for taking this course. We hope you enjoyed the lessons and the information you acquired in this course will be useful in the future. You can review the course as many times as you want, Review Close