Regulation 640/2009 of the EcoDesign Directive is now current and any motor with an efficiency rating less that IE2 can no longer be placed on the market. Specifically, the Regulations apply to LV motors of type S1 and S3 between 750W and 375kW. In the following article, Russell Maccabe, WEG Electric Motors’ UK sales manager, presents a detailed account and analysis of the legislation, and what it means for your business.
You can access a video interview with Russell Maccabe by clicking on the panel above. The interview, on the subject of the new motor efficiency regulations, was conducted at the recent IWEX show in Birmingham by DPA publisher Andrew Quenault.
Efficiency class IE2 forms part of the new harmonised European standard EN 60034-30:2009 which replaces the old voluntary Eff classes of electric motor efficiency rating, and represents the first phase of the implementation of higher efficiency levels for electric motors. The regulations are being introduced in Europe under EC Regulation 640/2009 dated 22/7/2009 which implements the Energy using Products (EuP) Directive 2005/32/EC.
What does it apply to?
As the new regulations apply to 3-phase asynchronous electric motors with rated voltages up to 1,000V in the power range between 0.75kW to 375kW in 2, 4 and 6 pole configurations and rated for continuous duty, it therefore applies to the vast majority of motors used in industry today.
Are there any exceptions to the IE2 rule?
The main leading manufacturers are embracing the move towards higher efficiency and putting in the necessary investments to improve the design and construction of their motors in order to meet not only IE2 standards, but also the even higher efficiency standards of IE3 and the future IE4 standard, although this final class seems to require some more advanced technology; for example, permanent magnet motors and motor matched inverter drives.
The exceptions detailed in the EC Regulation are as follows:
? Motors having 8 or more poles;
? Motors not rated for continuous duty (S1)
? Motors designed to operate wholly immersed in a liquid;
? Motors integrated into a product where energy performance cannot be tested independently from the product;
? Motors specifically designed to operate:-
o at altitudes exceeding 1,000 metres above sea-level;
o where ambient air temperatures exceed 40°C;
o in maximum operating temperature above 400°C;
o where ambient air temperatures are less than -15°C for any motor or less than 0°C for a motor with air cooling;
o where the water coolant temperature at the inlet to a product is less than 5°C or exceeds 25°C;
? In potentially explosive atmospheres (Ex motors);
? Brake motors
The regulations have been designed to slow down the current increase in energy used by electric motor driven systems as they account for 43-46% of the world’s energy consumption.
What are the classifications?
IE1 = Standard Efficiency, similar to the old Eff2
IE2 = High Efficiency, similar to the old Eff1
IE3 = Premium Efficiency, (no previous equivalent)
IE4 = Super Premium Efficiency (not yet fully defined)
Manufacturers' declared efficiency values, when comparing the old Eff standard with the corresponding IE code, are likely to differ slightly due to the new methods defined in IEC 60034-2-1:2007, and which have been incorporated within the IEC 60034-30 standard. Motor design has not necessarily changed, just the means by which the efficiency values are measured.
How can you tell if a motor complies?
The motors must be equipped with a rating plate containing data specified in IEC 60034-1. This shall also include details of the IE code and the efficiency value of the motor at 100% of its rated output at nominal voltage. Whilst the EC Regulation indicates that the efficiency values at 75% and 50% of rated load should also be shown on the motor nameplate, it is considered that this is unnecessary provided that this data is freely available in manufacturers' technical product documentation. Clarification of this point is currently being sought from the European Commission.
When do the regulations come into force?
There is a phased introduction of the new regulations beginning in 2011:
? 16 June 2011 - motors must meet the IE2 efficiency level as a minimum
? 1 January 2015 - motors from 7.5 to 375 kW must meet the higher IE3 efficiency level, or must be use an variable speed inverter drive
? 1 January 2017 - the 2015 regulations are extended down to motors of 0.75kW.
Do they just apply to new motors?
The regulations apply to all new motors, whether incorporated within new machines or existing installations, and in maintenance and retrofit applications. Existing stock at manufacturers warehouses, independent distributors or at machine manufacturers can still be sold or put in to service after 16th June 2011 provided it was placed on to the market on or before 15th June 2011.
The repairing and rewinding of currently installed motors is still permitted and the rewound motor does not have to comply with the Regulations.
What are the benefits?
Over the lifetime of an electric motor, energy costs amount to about 97% of the total costs of ownership. Therefore a 2-3% gain in efficiency can achieve significant long term savings. Based on 8,000 hours per year, stepping up an efficiency level can offer payback times on the extra investment of under two years. As a simple guide, if a motor is used for 2,000 hours a year or more, the general advice is to buy premium efficiency or high efficiency with inverter drive now.
What role do inverter drives play?
From 2015, IE2 motors equipped with a frequency inverter can be used instead of IE3 premium efficiency motors. This is an attractive alternative and the IE2 + inverter combination will generally yield greater savings compared with IE3 if variable speed is required. There is no obligation that the inverter will be integrated into the motor, although that is possible, and it is expected many customers will purchase motors and inverters from different sources.
Documentation requirements are not yet defined, but it would seem likely a degree of self-certification will apply. However, it will be necessary for the Manufacturer or his authorised representative to display on the motor itself, and in product information, the fact that an IE2 motor may only be utilised with a variable speed drive.
Do we need these regulations?
Many people would say the new regulations and efficiency bands are long overdue. In spite of the implementation of IE2 in Europe in June 2011, we are playing catch-up with countries like the USA and Australia who already have Minimum Efficiency Performance Standards (MEPS) above IE2. Ultimately the big winners are the end users who will benefit from lower energy costs and, more importantly, the Environment as a whole owing the reduction in CO2 emissions.
A condensed overview
Beginning in June 2011, electric motors within the scope of the EuP Directive will be required to meet the IE2 standard of energy efficiency. The motor efficiency ratings are based on the efficiency classes defined in the IEC 60034-30 standard published by the International Electrotechnical Commission (IEC). These range from IE1 (low efficiency) to IE4 (super-premium efficiency).
It will supersede the voluntary scheme based on the Eff efficiency classifications which has been running in Europe since 1998. Under the scheme, all single-speed, 2, 4 or 6 pole, three-phase squirrel-cage induction motors with output ratings from 0.75 to 375kW sold in the EEA will have to achieve at least the IE2 efficiency level from 16 June 2011 onwards.
In the second phase, which comes into force on 1 January 2015, motors rated from 7.5 to 375kW will either have to achieve the higher IE3 efficiency level, or meet the IE2 level and be utilised with a variable speed drive (VSD).
Finally, two years later, the same regulations will be extended to apply to motors down to 0.75kw. There are thus far no plans to make IE4 motors mandatory – efficiency values have yet to be defined for this class, which will cover 'super-premium' technologies such as permanent magnet (PM) motors.
Conclusions
Time to look at what the regulations are trying to achieve rather than just looking at compliance? The EU’s new eco-design directive 2005/32/EC is to be welcomed as it imposes mandatory minimum efficiencies for three-phase, low voltage electric motors for the first time.
However, when comparing the new classifications with the old voluntary Eff classifications for the same motor, it is expected that the efficiency levels deter-mined according to the new method will, in many cases, appear to be lower (particularly for smaller motors), primarily because the new testing methods in IEC 60034-2-1:2007 is more precise.
There is also a problem with the directive itself. Motors built specifically for use in hazardous areas are excluded. This is a major omission for two key reasons: first, the market for ATEX motors is large, reflecting the increasing growth in hazardous environments; second, the very nature of the operating environment means that ATEX motors tend to run for extended periods, consuming large amounts of energy.
What is clear at present is that the gradualism of this approach is not fit for purpose, where carbon emissions are approaching the threshold for critical parts per million in the atmosphere. It’s time for another approach, and this starts with the acceptance that the standard 3-phase squirrel cage design of electric motor, which has been around for over a century, has probably achieved its optimum levels of performance.
However, the squirrel cage design is very robust and reliable, and well proven in operation; it is also relatively inexpensive, which, up till now, has meant that more efficient new technology designs, such as permanent magnet (PM) motors, have not been widely adopted or applied.
This situation has to change, and PM motors have to become more widely used if industry is to make a real impact in emissions reduction. The benefits of using PM speak for themselves: compared to equivalent size induction motors, the latest generation of PM motors reduce motor size by up to 50%, weight by up to 36% - and deliver higher efficiencies (up to 97.5%). In addition, they are, generally, at least one frame size or core length smaller than the equivalent induction motor, and in some cases can be two frame sizes smaller.
PM motors are manufactured with high energy magnets in their rotors; these deliver a significant reduction in energy losses compared to an induction motor, generally resulting in a lower temperature rise, and increased operating life. In addition, as these energy losses account for a significant proportion of total losses in induction motors, the PM motor delivers much higher efficiencies; in most cases easily exceeding the new harmonised IE (International Efficiency) standard, IE3 (from 2015). Also, importantly, most designs even attain the yet-to-be-ratified IE4 standard.
My thanks to Russell Maccabe for providing this comprehensive guide to the new motor efficiency regulations. For more information about WEG UK and its products, click here.
And while we are on the subject of energy efficiency, I'd just like to add this thought from GAMBICA deputy director, Steve Brambley:
"Imagine for a moment this idyllic situation; you buy shares in a company where the return is guaranteed. People would queue up to invest their money in this new, risk free, stock market. Although such utopian circumstances don’t apply to the FTSE, they do apply to variable speed drives (VSDs). However, there isn’t a queue to buy these devices; perhaps because of a lack of understanding of the ROI they deliver.
"Installing a variable speed drive is the closest thing industry has to signing up for free money. They can reduce the energy bill on your application or system by more than the capital cost in a relatively short period. Furthermore, like our utopian stocks, a VSD will pay yearly dividends - in the form of reduced energy bills. As energy prices continue to soar, the ROI on a VSD application increases in proportion to the bill. (Although I’m sure we would rather just keep the bills low.)
"Perhaps greater awareness is required? Perhaps engineers should pay closer attention to the lifetime cost, including energy, of a system, rather than just its capital cost? Or perhaps finance and purchasing teams need to be made aware of what engineers already know – that VSDs are the lowest risk investment UK plc can make to bring its environmental and economic goals a step closer to fruition."
Les Hunt
Editor
Reader comments:
From retired plant engineer, Steve Moore:
My understanding, as a mechanical engineer, was that the high efficiency motors appearing some years ago needed to be running at 80% or more of full load current to be effective. A plant survey we conducted showed 50% or more of our motors were less than 80%. Therefore the likely savings due to this apparent higher efficiency were marginal or nil in many cases. Do the newer generation of high efficiency motors avoid this?
It would seem a check on design intent and execution versus actual operation would be advisable.
The use of variable speed is to be commended but needs careful application as just putting it on everything will lead to waste effort as some applications e.g. high static head pump applications with small range requirements. I remember one duty where we replaced an expensive alloy control valve with an orifice plate; much cheaper.