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FEATURE
DRIVES, CONTROLS & MOTORS
NEW EU LEGISLATION E EFFICIENCY OF INDUSTR
The EU has been introducing a comprehensive framework aimed at enhancing the efficiency of electric motors used in industrial processes. A graduated process has been raising the minimum efficiency standards of new motors, broadening the scope of machines
that are covered and widening the applications included. Jeremy Wilkinson, global product manager at Control Techniques, looks at how the latest EU directive will affect businesses and how a proactive approach can achieve greater energy savings
T
he EU Commission estimates that large electric motors – numbering around 80 million – consume approximately 65-70%
of the energy used in industrial applications. The new EU Regulation 2019/1781 of directive 2009/125/EC (Energy related products) came into force on 1st July 2023, aimed at reducing energy consumption across all member states. Beginning in 2009, the Commission set
key measures to cut energy usage by issuing legislation covering the eco-design requirements of energy related products, namely electric motors and variable speed drives (VSDs).
THE LATEST LEGISLATION Earlier drafts required the majority of new 3-phase motors between 0.75kW and 375kW to be designed to IE3 (Premium Efficiency) or IE2 (High Efficiency) levels and installed with a VSD. In July 2021, the IE3 compliance band was expanded up to 1000kW and the scope was widened to include motors fitted with brakes, most ATEX motors, as well as motors for fan and blower applications using a totally enclosed air over (TEAO) design. At the same time, VSDs were required to meet the same rules as direct-on-line (DOL) motors. Now, however, the latest legislation has landed – and it requires all new, non-Ex eb, 3-phase, 2-6 pole, single-speed electric motors between 75 kW and 200 kW, to be Super Premium Efficiency (IE4). In addition, most ATEX motors need to be IE3 and all single-phase motors need to have a minimum IE2 rating. The drive for greater
energy efficiency has also encouraged the use of VSDs, which can be used in conjunction with the electric motor to improve control and efficiency. Previously, the minimum requirement for new equipment was an IE3 motor or an IE2 motor
20 DESIGN SOLUTIONS MARCH 2024
plus a VSD to deliver an efficiency that is equivalent to or better than IE3 efficiency rating.
FINDING A SOLUTION Specifiers and end users need to decide which option as a combination will provide the most efficient solution for their application. An IE3 motor has a clearly specified efficiency rating at its rated speed and at 50%, 75% and 100% load. An application that requires variable speed
adjustments and different loadings cannot be evaluated at present with the available product performance data. A specifier or an end user is currently unable to compare the different competitive components of the drive system and finally choose the most efficient motor and inverter components.
A similar situation arises when the motor
is integrated into a product, such as a fan or a pump, where the motor’s performance cannot be measured independently from the product. In order to address these situations and to improve the potential energy savings in these areas, a new standard, EN50598, has been developed, which benchmarks the efficiency ratings of power drive systems (PDS).
VIEWING THE COMPLETE SYSTEM EN50598-1 sets out the general requirements for setting energy efficiency standards for power
driven equipment using the extended product approach (EPA), and semi analytic model (SAM). This essentially covers the combined efficiency ratings for the PDS and the driven equipment such as the pump, gearbox, compressor, etc. EN50598-2 widens the focus from a single
component to the efficiency of the complete power drive system (PDS). The new efficiency classes (IES) provide a structure that allows the losses for a complete drive system to be compared. The median range is IES1, and systems that fall below the minimum value of IES1 are classed as IES0. More efficient systems, with values 20% above IES1, are identified as IES2. EN50598-3 provides a quantitative eco-design
approach through life cycle assessment, including product category rules and the content of environmental declarations. These new standards will also help end
users to gauge payback periods more accurately. Previously, the overall efficiency of speed-controlled motors was estimated using rough energy consumption figures. Now, with verified efficiency curves, the payback period for a motor/drive combination can be calculated more realistically.
The right drive system will ensure energy savings
DRIVE MANUFACTURERS For manufacturers of VSDs there is a requirement to provide efficiency data according to the part load measurement points as defined for the CDM system, while those producing motors do not have to provide the efficiency data at the specified part load. The Ecodesign Directive, 2009/125/EC, is also known as the Energy Related Products (ErP) Directive and relates to all products with a certain energy savings potential, which certainly
includes VSDs. In many cases, the best solution for a
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