NEWS n 5 ABB shrinks IE5 synchronous reluctance motors down to 750W ABB HAS EXPANDED ITS portfolio of IE5-efficiency synchronous reluctance (SynRM) motors by adding three smaller frame sizes (90, 100 and 112), spanning ratings from 0.75–450kW. The motors can cut energy losses by up to 40% compared to IE3 motors, resulting in payback periods as short as five months, the company says. ABB claims that it now offers the broadest range of magnet- and rare-earth-free motors on the market. It is now producing SynRM machines in frame sizes from 90–132. The company reckons that over a 20-year period, a 90kW SynRM motor could save €79,800 ($94,000) in energy costs and cut CO2 emissions by 95,760kg. With industrial sites typically operating dozens or even hundreds of smaller motors, as well as larger ones, these savings and environmental benefits can multiply substantially, it adds. The new motors, with their extended power options and operating speeds of up to 3,600 rpm, are suitable www.drivesncontrols.com October 2025 for pump, fan and compressor applications. They will cost around 10% more than similarly rated induction motors, but when the cost of a variable-speed drive (which is essential for SynRM motors) is included, the differential will be smaller. “Smaller motors are often deployed in high volumes and in continuous-duty or space-constrained environments where thermal performance, precise control, and high efficiency under partial load are critical”, says Stefan Floeck, president of ABB’s IEC LV motors business. “With our expanded SynRM range, we’re ensuring that every motor, no matter the size, plays its part in helping boost productivity for our customers while cutting emissions.” Since ABB launched its first SynRM drive in 2011, it has broadened the range to include variants such as liquid-cooled versions, and motors for explosive atmospheres. In 2024, it introduced “IE6” SynRM motors in ratings above 90kW that deliver up to 20% lower losses than IE5 machines, even though there is no official definition of IE6 yet. ABB says it may extend the IE6 ratings to the smaller SynRM motors if there is a demand. As well as cutting energy use by up to 40%, SynRM motors operate with winding temperatures that are up to 30% lower than induction machines, and bearing temperatures that are up to 15% lower, helping to improve their reliability and reducing the need for servicing and maintenance. Bearings are the biggest cause of failures in induction motors, often as a result of overheating. Daniel Eberli, ABB’s business line manager for process performance motors, points out that the high efficiencies and outputs of synchronous reluctance motors mean that OEM machine-builders can produce more powerful machines that are the same size – or smaller machines that are just as powerful as versions with less efficient drives. One recent project that has made extensive use of SynRM motors is at a site in Bulgaria operated by Europe’s largest copper producer, Aurubis. It has replaced 460 outdated motors with a combination of 265 IE5 SynRM machines for variable-torque loads, and 181 IE4 induction motors for constanttorque loads. The upgrade is delivering annual energy savings of 28%, resulting in a return on investment of just 3.5 years, as well as delivering a 12,000tonne reduction in CO2 emissions. Another application is at an aquatic centre in Hobart, Tasmania, which was threatened with closure because of its high energy bills. The centre has been able to stay open by installing 19 SynRM motors and drives, cutting the centre’s energy consumption by 18%, saving 259MWh of electricity a year, and slashing its energy bills by $36,000 AUD (£17,740). www.abb.com ABB’s smallest synchronous reluctance motors are now rated at just 750W SCHNEIDER ELECTRIC HAS OPENED its £42m state-of-the-art smart plant in Scarborough, North Yorkshire, which will manufacture electrical equipment needed for the move to cleaner energy. The 16,500m2 plant, which was announced last year, is due to be fully commissioned by the end of this year, and is expected to create more than 200 jobs. The factory will act as a blueprint for sustainable design for Schneider’s manufacturing operations worldwide. Netzero in Scope 1 and 2 emissions, the plant uses modern technologies to cut energy waste. Almost a third of its power will come from its own solar energy system. By manufacturing locally for UK customers, Schneider Electric says it is building resilience into the nation’s critical electrical infrastructure, reducing its exposure to global supply chain shocks, and slashing costs and carbon emissions through shorter, optimised transport and logistics routes. UK production will mean faster, more flexible delivery of bespoke engineering systems, tailored to the needs of UK projects. Customers will be able to visit the site, work with product designers and engineers, and ensure that products meet their needs before manufacturing begins. The site will produce equipment to meet British standards, making it ready for export to Commonwealth markets. “UK manufacturing is the backbone of the nation’s infrastructure drive,” says Kelly Becker, president of Schneider Electric in the UK & Ireland, Belgium & Netherlands. “With electricity demand set to hit new heights, our Scarborough site – rooted in Yorkshire expertise – gives us the scale and agility to respond quickly to market changes and support the UK’s energy transition and beyond. By expanding our local footprint, we’re working even closer with customers to deliver a decarbonised, resilient energy system for the future.” Schneider’s £42m smart factory in Scarborough nears completion
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