Boosting Energy Efficiency with SIRIUS Industrial Controls

Boosting Energy Efficiency with SIRIUS Industrial Controls siemens.com/sirius/energysaving

Answers for industry.

Energy savings in industrial applications:

SIRIUS Industrial Controls for Minimized Consumption

Against the background of continuously rising energy costs, ever stricter environmental regulations as well as intended certification in accordance with the ISO 50001 standard on energy management, operational energy management is increasingly gaining importance in the industrial sectors. Energy efficiency represents a decisive lever in this context as it decisively contributes to increased system productivity and thus to improved competitiveness – in all sectors. SIRIUS Innovations impressively prove that efficient energy management already starts in the control cabinet – and facilitates enormous saving potentials also in fixed-speed drive applications.

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SIRIUS Innovations support you with increasing your energy efficiency – in three respects. First of all, our trend-setting low-voltage controls and distribution products are energy-efficient to start with and are characterized by their extremely low intrinsic power loss, which not only minimizes energy costs, but also reduces the waste heat inside the control cabinet. This facilitates an increased packing density in the control cabinet and reduced cooling power. Furthermore, our communication-capable switching devices detect measured values relevant for energy management and transfer the consumption data to superior energy management systems such as B.Data. The resulting transparency allows for the clear identification of “energy eaters”. Finally, SIRIUS industrial controls also play an important role when it comes to the selection and configuration of energy-optimized drive solutions for the most varying applications.

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Energy efficiency in the field of low-voltage controls & distribution

Realize Siemens offers a unique portfolio of hardware and software solutions for the implementation of efficient energy management. The portfolio covers the following phases: • I dentify: Detection and visualization of energy flows as well as identification of major energy consumers •E  valuate: Assessment of saving potentials and derivation of potential efficiency-increasing measures for the specific application case •R  ealize: Effective utilization of the determined saving potentials by means of specific measures

Targeted disconnection of inactive loads: PROFIenergy SIRIUS Innovations Energy-efficient products

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Biggest lever for energy savings

The optimum organization of processes in terms of energy efficiency not only depends on the measuring of energy flows and the application of energy-efficient products. The biggest lever for energy savings can be identified when taking a closer look at the application: Required number of switch-on and switch-off operations, required speed, application runtime, etc.

PROFIenergy represents a profile based on the PROFINET Ethernet standard via which loads can be coordinated in a device-spanning manner and centrally disconnected during production breaks. As a result, electricity can be reasonably saved even during short breaks without laborious manual switching. The new SIRIUS M200D motor starters with PROFIenergy support the selective disconnection of loads and thus ensure significantly reduced energy costs. Existing hardware and software can be easily integrated in the energy management system via the PROFI-energy capable power module of SIMATIC ET 200S as well as via function blocks in the controller. In connection with the I-Device functionality of PROFINET, PROFIenergy also facilitates the coordinated disconnection and connection of complete system parts. The reloadable function blocks ensure minimized configuration expenditures. Furthermore, standardized measured value formats ease the evaluation of available data.

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Systematically Increased Energy Efficiency: SIRIUS • Reduction of mechanical and electrical peak loads by up to 60 % thanks to the application of SIRIUS motor starters and soft starters • Further 10 % reduction of intrinsic power loss with SIRIUS switching and protection devices of the new generation • Significant cost savings thanks to the complete disconnection of redundant loads during production breaks via PROFIenergy • Competent support with the conversion from existing drives to ecological systems by our customer support • Elimination or extensive minimization of expenditures for heat dissipation and resulting savings in terms of operating costs caused by control cabinet air-conditioning • Overall energy analysis of the drive train – for determination of the best, energy-optimized application solution for fixed speed, variable speed or a combination of both (cascade operation) • Comprehensive CAx data for industrial controls 12 data types for considerably reduced engineering expenditures 4

Planning efficiency Planning efficiency both refers to a concept and a specific offer for more effective control cabinet planning – on the basis of support throughout the entire planning and documentation process. The focus lies on high-quality and individual product data. Engineering expenditure reductions of up to 80 % A genuine benefit free of charge: As your partner, we support you with the significant reduction of your configuration expenditures. Our CAx application consulting helps you eliminate the laborious compilation of product information, doing away with manual product data entry. All in all, this facilitates time savings of up to 80 %.

Practically Proven: SIRIUS Industrial Controls in Application-Specific Solutions Utilization of all levers – for increased energy efficiency in the automotive industry Integrated productivity represents a decisive success factor in the field of conveyor technology. Intelligent energy management significantly contributes to this target. Comprehensive energy efficiency necessitates the implementation of holistic systems and solutions – also in the automotive industry. As a first step, the actual consumption has to be identified and allocated to the cause. With SIRIUS switching devices, measured value detection is frequently already integrated onboard. This functionality continuously supports energy data management systems (such as B.Data) by providing the required information. This way, specific measures can be specified for the targeted increase of energy efficiency. In this context, motors play a key role: They account for a majority of the energy consumption within a system. The saving potentials which can be utilized with highly efficient motors are correspondingly high. Energy-efficient motors from the Siemens portfolio suggest themselves for automatic transport from one station to the next. SIRIUS soft starters ensure material-sparing and energy-saving ramp-up to the target speed. Furthermore, part of the energy required for braking of the conveyor technology components is recovered and fed back into the mains via SINAMICS frequency converters.

SIRIUS switching and protection devices significantly contribute to increased energy efficiency: On the one hand, the devices’ intrinsic power loss is very low and on the other hand, their temperature rise during operation is considerably lower than with comparable solutions. This allows for a reduced dimensioning of the control cabinets’ cooling, which in turn facilitates savings in terms of energy consumption and system investment. Last but not least, compact SITOP power supply units ensure minimized heat and energy with regard to the 24 V supply. Thanks to their high efficiency throughout the entire load range, they supply control cabinets with controlled DC voltage in a highly efficient manner

Advantages • Significant energy and cost savings through perfectly matched overall system – from a single source • Material-sparing and energy-saving motor start-up with SIRIUS soft starters • Recovery of the required braking energy via SINAMICS frequency converters 5

Sewage plant and water industry: Pump operation only if required As operation of the pumps in the sedimentation tank is only required when the water volume in the tank reaches the minimum level, an automatic switch-on and switch-off function for the pump is recommendable. With SIRIUS industrial controls, pumps and drives are only connected when required and are out of operation during the remaining time. Besides reduced device stress, this also entails considerable saving potentials in terms of energy costs compared to other drive concepts.

Advantages • Reduction of peak loads by up to 60 % • Approx. 30 % energy cost savings compared to other solutions • Avoidance of loads such as water hammers thanks to soft start-up and ramp-down • Prolonged service life of the motors thanks to soft start-up and ramp-down

Pump technology: Savings through cascade circuit A cascade circuit of frequency converter and soft starters offers an optimum combination of switching and converter technology. In the example application, one frequency converter and three soft starters facilitate purchase cost savings amounting to approximately 12,000 Euro compared to the application of four frequency converters. Depending on the water demand, the base load can be controlled by up to three pumps, while the fourth pump covers the variable demand. This supports annual energy cost savings of up to 5,000 Euro* and CO2 emission reductions of approx. 26 tons per year.

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Frequency converter 3 x soft starter Pump 0 – 90 kW Pump 90 kW adjustable base load

• Avoidance of peak loads thanks to the application of SIRIUS industrial controls • Minimization of current peaks by approx. 60 %

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• Minimization of total energy costs by approx. 65 % • Reduction of purchase costs by approx. 70 % compared to conventional solutions

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With the cascade circuit, a frequency converter serves the variable demand (orange); the base load is switched via soft starters (green)

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• Prolonged service life of motors thanks to more gentle operation • Optional flow rate adjustment without throttle valves * Calculation example with 12 Cent/kWh

Ventilation and cooling in a greenhouse: Temperature-dependent 2-point control The compensation of temperature deviations represents an important requirement in industrial greenhouses. In this context, the automatic detection of temperature conditions and the resulting switch-on and switch-off processes of the ventilation system decisively contribute to minimized energy consumption. In our application case, a temperature-dependent two-point control which switches and controls the ventilation and cooling process in an energy-efficient manner was installed on the basis of SIRIUS industrial controls. Advantages • Energy-efficient operation thanks to low power loss • Space-saving assembly of SIRIUS industrial controls in the control cabinet • Autonomous operation of the entire ventilation and cooling system • Increased overall operating efficiency coupled with reduced energy costs

Snowguns: Efficient water supply with large height differences Snowmaking on ski slopes requires an efficient, demand-based water supply. In the specific application case, three pumps with SIMOTICS IE3 motors are effectively installed in series. The booster pump and the pump in the slide gate valve station are controlled and protected by SIRIUS soft starters and industrial controls.

Storage reservoir Ski slope

Snwomakers

Storage reservoir 170,000 m3

Slide gate valve station, static pressure, pump with soft starter

Main pump pumping station 1, controlled pressure up to 100 bar, pump on converter Booster pump pumping station 1, constant pressure of 5 bar, pump with direct-on-line starter

Height difference approx. 1.000 m, withdrawal points for snowmakers approx. every 100 m to 150 m

Soft starters facilitate soft start-up without current peaks. The main pump, which supplies the individual snowmakers with water in a demand-based manner via a SINAMICS frequency converter, is connected in series with the booster pump. Compared to conventional throttle control for the snowmakers’ supply over a height difference of 500 meters, this solution supports significant savings amounting to up to 2,000 Euro and 15 tons of CO2 per year.

Advantages • Reliable water supply with height differences of up to 1,000 meters • Low peak loads thanks to energy-saving soft starters • Constant water pressure of 5 bar • Annual cost savings of 2,000 Euro compared to other solutions • Annual CO2 savings of 15 tons compared to other solutions 7

For further information: Please contact your local Siemens sales partner. In case of technical questions, please contact: Technical Assistance Tel. +49 911 895-5900 E-mail: [email protected]

Siemens AG Industry Sector Industry Automation Control Components and Systems Engineering P.O. Box 23 55 90713 FUERTH GERMANY

Subject to changes 08/12 Order No.: E20001-A310-P301-X-7600 Dispo 27900 SCHÖ/43157 MI.CE.SE.XXXX.52.2.02 WS 07125.0 Printed in Germany © Siemens AG 2012

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The information provided in this brochure contains merely general descriptions or characteristics of performance which in actual case of use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract All product designations may be trademarks and product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.