THE IE2 ELECTRIC MOTORSPECIFICATION GUIDE

WEG’S RUSSELL MACCABEPRESENTS A DETAILED

ACCOUNT AND ANALYSISOF THE NEW MOTOR

EFFICIENCY LEGISLATION,AND WHAT IT MEANS

FOR YOURBUSINESS

ABB’S STEVERUDDELL WELCOMESTHE INTRODUCTIONOF MINIMUMEFFICIENCY LEVELSFOR LV MOTORS

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July 2011

What is the IE2 efficiency class? Efficiency class IE2forms part of the new harmonised Europeanstandard EN 60034-30:2009 which replaces the old

voluntary Eff classes of electric motor efficiency rating, andrepresents the first phase of the implementation of higherefficiency levels for electric motors. The regulations are beingintroduced in Europe under EC Regulation 640/2009 dated22/7/2009 which implements the Energy using Products (EuP)Directive 2005/32/EC.

What does it apply to?As the new regulations apply to 3-phase asynchronouselectric motors with rated voltages up to 1,000V in the powerrange between 0.75kW to 375kW in 2, 4 and 6 poleconfigurations and rated for continuous duty, it thereforeapplies 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 movetowards higher efficiency and putting in the necessaryinvestments to improve the design and construction of theirmotors in order to meet not only IE2 standards, but also theeven higher efficiency standards of IE3 and the future IE4

standard, although this final class seems to require somemore advanced technology as for example permanentmagnet 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:-

• at altitudes exceeding 1,000 metres above sea-level;• where ambient air temperatures exceed 40ºC;• in maximum operating temperature above 400ºC;• where ambient air temperatures are less than -15ºC for

any motor or less than 0ºC for a motor with air cooling;• where the water coolant temperature at the inlet to a

product is less than 5ºC or exceeds 25ºC;• In potentially explosive atmospheres (Ex motors);• Brake motorsThe regulations have been designed to slow down thecurrent increase in energy used by electric motor drivensystems as they account for 43-46% of the world’s energyconsumption.

In this essential guide to the new motor efficiency regulations, you will find all the basicinformation you need to get a practical perspective on what is required by law, what the regulations include, what they don't include, what choices you have to make andfinally some examples that illustrate what is at the core of this policy - energy saving.Russell Maccabe reports

WEB EXCLUSIVE

WEG believes that IE2and IE3 standardmotors provide a betterreturn-on-investmentas they are available to buy without asignificant costpremium. Sizes from0.75KW through to1MW are alreadyavailable from thecompany

dpaonthenet.net

THE NEW ENERGYEFFICIENCY REGULATIONSFOR ELECTRIC MOTORS

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What are the classifications?IE1 = Standard Efficiency, similar to the old Eff2IE2 = High Efficiency, similar to the old Eff1IE3 = Premium Efficiency, (no previous equivalent)IE4 = Super Premium Efficiency (not yet fully defined)

Manufacturer's declared efficiency values, when comparing theold Eff standard with the corresponding IEcode, are likely to differ slightly due to thenew methods defined in IEC 60034-2-1:2007, and which have beenincorporated within the IEC 60034-30standard. Motor design has notnecessarily changed, just the means bywhich the efficiency values are measured.

How can you tell if a motorcomplies?The motors must be equipped with arating plate containing data specified inIEC 60034-1. This shall also includedetails of the IE code and the efficiencyvalue of the motor at 100% of its ratedoutput at nominal voltage. Whilst the ECRegulation indicates that the efficiencyvalues at 75% and 50% of rated loadshould also be shown on the motornameplate, it is considered that this isunnecessary provided that this data isfreely available in Manufacturer ’s

technical product documentation. Clarification of this point iscurrently being sought from the European Commission.

When do the regulations come into force?There is a phased introduction of the new regulationsbeginning 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 use an variablespeed inverter drive

• 1 January 2017 - the 2015 regulations are extended downto motors of 0.75kW

Do they just apply to new motors?The regulations apply to all new motors, whetherincorporated within new machines or existing installations,and in maintenance and retrofit applications. Existing stock atmanufacturers warehouses, independent distributors or atmachine manufacturers can still be sold or put in to serviceafter 16th June 2011 provided it was placed on to the marketon or before 15th June 2011.

The repairing and rewinding of currently installed motorsis still permitted and the rewound motor does not have tocomply with the Regulations.

What are the benefits?Over the lifetime of an electric motor, energy costs amount toabout 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 efficiencylevel can offer payback times on the extra investment ofunder two years. As a simple guide, if a motor is used for2,000 hours a year or more, the general advice is to buypremium efficiency or high efficiency with inverter drive now.

What role do inverter drives play?From 2015, IE2 motors equipped with a frequency invertercan be used instead of IE3 premium efficiency motors. This isan attractive alternative and the IE2 + inverter combinationwill generally yield greater savings compared with IE3 ifvariable speed is required. There is no obligation that theinverter will be integrated into the motor, although that ispossible, and it is expected many customers will purchasemotors and inverters from different sources.

Documentation requirements are not yet defined, but itwould seem likely a degree of self-certification will apply.However, it will be necessary for the Manufacturer or hisauthorised representative to display on the motor itself, andin product information, the fact that an IE2 motor may only beutilised with a variable speed drive.

Do we need these regulations?Many people would say the new regulations and efficiencybands are long overdue. In spite of the implementation of IE2 inEurope in June 2011, we are playing catch-up with countrieslike the USA and Australia who already have MinimumEfficiency Performance Standards (MEPS) above IE2. Ultimatelythe big winners are the end users who will benefit from lowerenergy costs and, more importantly, the Environment as awhole owing the reduction in CO2 emissions.

A condensed overviewBeginning in June 2011, electric motors within the scope ofthe EuP Directive will be required to meet the IE2 standard ofenergy efficiency. The motor efficiency ratings are based onthe efficiency classes defined in the IEC 60034-30 standardpublished 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 Effefficiency classifications which has been running in Europesince 1998. Under the scheme, all single-speed, 2, 4 or 6 pole,three-phase squirrel-cage induction motors with output ratingsfrom 0.75 to 375kW sold in the EEA will have to achieve atleast the IE2 efficiency level from 16 June 2011 onwards.

In the second phase, which comes into force on 1 January2015, motors rated from 7.5 to 375kW will either have toachieve the higher IE3 efficiency level, or meet the IE2 leveland be utilised with a variable speed drive (VSD).

Finally, two years later, the same regulations will be extendedto apply to motors down to 0.75kw. There are thus far no plansto make IE4 motors mandatory - efficiency values have yet to bedefined for this class, which will cover ‘super-premium’technologies such as permanent magnet (PM) motors.

ConclusionsTime to look at what the regulations are trying to achieverather than just looking at compliance? The EU’s new eco-design directive 2005/32/EC is to be welcomed as it imposes

July 2011

WEB EXCLUSIVE

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WEG has jumped ahead of the new IE2 electric motor energy efficiencystandards, coming into effect in Europe in June of this year, bylaunching W22X, a full range of explosion proof IE2, and IE3 standard

high-efficiency electric motors. Choosing not to take advantage of exemptions inthe EU regulations which it claims provide a get-out clause for companiesselling lower efficiency motors into hazardous areas, WEG believes that IE2 andIE3 standard motors provide a better ROI as they are available to buy without asignificant cost premium. Sizes from 0.75kW through to 1MW are alreadyavailable and were on show at Hannover Fair 2011.

MANUFACTURER LAUNCHESIE2 EFFICIENCY MOTORRANGE WHERE REGULATIONSDO NOT REQUIRE IT

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WEG was a majorexhibitor at this year’s

IWEX show inBirmingham

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July 2011

mandatory minimum efficiencies for three-phase, low voltageelectric motors for the first time.

However, when comparing the new classifications withthe old voluntary Eff classifications for the same motor, it isexpected that the efficiency levels determined according tothe new method will, in many cases, appear to be lower(particularly for smaller motors), primarily because the newtesting methods in IEC 60034-2-1:2007 are more precise.

There is also a problem with the directive itself. Motorsbuilt specifically for use in hazardous areas are excluded. Thisis a major omission for two key reasons: first, the market forATEX motors is large, reflecting the increasing growth inhazardous environments; second, the very nature of theoperating environment means that ATEX motors tend to runfor extended periods, consuming large amounts of energy.

What is clear at present is that the gradualism of thisapproach is not fit for purpose, where carbon emissions areapproaching the threshold for critical parts per million in theatmosphere. It’s time for another approach, and this starts withthe acceptance that the standard 3-phase squirrel cage designof 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 andreliable, and well proven in operation; it is also relativelyinexpensive, which, up till now, has meant that more efficientnew technology designs, such as permanent magnet (PM)motors, have not been widely adopted or applied.

This situation has to change, and PM motors have tobecome more widely used if industry is to make a real impactin emissions reduction. The benefits of using PM speak forthemselves: compared to equivalent size induction motors, thelatest generation of PM motors reduce motor size by up to50%, weight by up to 36% - and deliver higher efficiencies (upto 97.5%). In addition, they are, generally, at least one framesize 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 intheir rotors; these deliver a significant reduction in energylosses compared to an induction motor, generally resulting ina lower temperature rise, and increased operating life. Inaddition, as these energy losses account for a significantproportion of total losses in induction motors, the PM motordelivers much higher efficiencies; in most cases easilyexceeding the new harmonised IE (International Efficiency)standard, IE3 (from 2015). Also, importantly, most designseven attain the yet-to-be-ratified IE4 standard. We woulddraw your attention to two examples provided by WEG,which are presented in the panels on this page.

Russell Maccabe is UK sales manager at WEG ElectricMotors UK

WEB EXCLUSIVE

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Engineering Steel Belgium (ESB) issaving €45,000 per annum on theoperation of three cooling pumps on

one of its electrical steel furnaces, since theinstallation of three WEG W22 132 kW, IE2high efficiency motors, controlled by WEGCFW-09 variable speed drives.

ESB, based in Seraing, Belgium, producessteel and related products for transport,energy generation, and aeronautics industriesin Belgium. Its products include carbon andlightly alloyed steel, in the form of cylindricalcontinuous cast blooms, and bottom poured

ingots for the manufacturers of open andclosed die forgings, seamless rolled rings,train wheels, seamless tubes, and extrudedparts, as well as bar rolling mills.

ESB conducted an audit of the operatinghours of the pump system. Based upon thisaudit ESB calculated that the total annual cost foroperating the pumps on the cooling system was€117,000; this figure based on an energy cost of€0.09/kWh. On the basis of this figure it wascalculated that further significant energy savingcould be achieved by the application of variablespeed drives to the pump motors, in conjunction

with a PLC-based process automation system.The benefits of the installation were

immediately apparent, normal weekdayoperation between 3pm and 8pm required theoperation of just one pump, and this running at70% of maximum speed, due to the variablespeed control provided by the WEG CFW-09drive. From 8pm to 11am, two pumps are inoperation, running at 89.2% of maximumspeed, also due to VSD control. At weekendsand the Christmas shutdown, when frost couldbe a problem, two pumps are still required,operating at 89.2% of maximum speed.

CASE STUDY: IE2 EFFICIENCY MOTORSPAY OFF IN THE STEEL INDUSTRY

CASE STUDY: IE3 EFFICIENCYMOTORS DELIVER MAJORSAVINGS AT ONE OF WORLD’SLARGEST FOOD PRODUCERS.

Working together with the global food producer, WEG carried out studiesto find the best ways to save energy, rationalise operations and updatethe production at a soya bean complex in Brazil.

Several improvement opportunities were identified, including re-powering offan motors on the site with W22 premium efficiency motors, and the installationof frequency inverters on the motors for the 200hp and 60hp fans. The invertersmade it possible to eliminate the mechanical dampers used on the fans, achievingmuch higher efficiency from the fan drive motors, saving US$ 14,512/year andUS$ 42,500/year on the operation of the 60hp and 200hp motors respectively. Thecomplete savings breakdowns are shown below:

Energy efficiency results with 60hp motor:• Savings of 37kWh.• Estimated savings of 144,607kWh of electricity per year.• Return on investment: 11 months.• Energy savings with motor + frequency inverter: US$ 14,512/year.• Investment with motor + frequency inverter: US$ 12,236Application engineering results with 200hp motor:• Savings of 48kWh.• Estimated savings of 509,416 kWh/year. • Return of investment of repowering the motor to 150hp, W22: 7 months.• Energy savings with motor + frequency inverter: US$ 42,500/year.• Investment with motor + frequency inverter: US$ 23,360

The author, Russell Maccabe

CLICK HEREFOR OUR VIDEO GUIDE TO IE2

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Motors | Automation | Energy | Transmission & Distribution | Coatings

We can’t predict the future

but we can see it coming.

Meeting the IE2 standard for motors is mandatory from

June 2011, WEG motors already exceed it. The IE3

standard won’t be enforced until 2015 but WEG already

produces Premium Efficiency IE3 Motors. No date has

been confirmed for the IE4 rating but you can already

choose a super efficient IE4 motor from WEG.

Being ahead of the game is what we call WEGnology…

If you want to get ahead, visit www.weg.net

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Energy, the environment and economics

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