March 2020

64 n MOTORS March 2020 www.drivesncontrols.com Efficiency regs will extend to hazardous area motors T here are more than 8 billion electric motors in use in Europe, consuming about 63% of all electricity generated across the continent. Until recently, some of these motors, including those designed for hazardous areas, were exempt from energy efficiency regulations, but these regulations are about to change to include a wider range of machines. And, starting in January 2021, VSDs (variable-speed drives) will be included to help achieve higher efficiencies, for the first time. In 2009, the EU Commission introduced its Minimum Energy Performance Standard (MEPS) in Regulation EC 640/2009. This required motors from 0.75–375kW to comply with international efficiency standards for single-speed three-phase motors set by the IEC. IE1 describes standard efficiency, IE2 is high efficiency, and IE3 is used for motors with premium levels of efficiency. Updates to the legislation in 2016 specified that electric motors need to be at least IE3, or IE2 if used with a VSD. This regulation, bolstered by improved design and materials for electric motors, brought about huge reductions in the amount of energy consumed by motors. Unsurprisingly, the electric motor market rapidly reflected the shift in the rules and moved to more efficient motors. Motors rated at IE1 and below, which had accounted for 80% of the Europeanmarket in 2009, held onto just 17% by 2016. During the same period, IE3 premium-class motors rose from 0% to 29%. Good news for the planet and cost savings for end-users. Now, the European Commission’s ecodesign committee has approved a new, stricter version of its requirements, which will take effect from January 1, 2021. Previously, the regulations covered only three-phase motors from 0.75–375kW, and excluded motors outside this range. From 2021, the regulations will require all new 2-, 4-, 6- and 8-pole motors in the range 0.75– 1,000kW to achieve IE3 efficiencies. The previous legislation that allowed an IE2 motor to be used provided it was controlled by a VSD, will no longer be valid. Motors from 0.12–0.75kW will need to be IE2. Special-purpose motors, such as explosion- or flame-proof motors were exempt from the previous regulation, out of precaution for the higher-risk environments in which they were used. From January 2021, new Atex motors entering the supply chain will have to be rated at IE3 or above, with Ex eb increased safety motors being an exception. These will need to be at least IE2 by 2023. High-efficiency motors for hazardous environments have been available for decades but, with no requirement to implement high levels of efficiency in hazardous environments, some businesses opted for low-efficiency motors, due in part to their cheaper upfront costs. In energy-intensive industries, such as chemicals, pharmaceuticals or oil and gas, thousands of motors operate for 24 hours a day. Even a slight improvement in efficiency, extrapolated over the number of motors in use and hours of operation, can benefit a business’ bottom line. The energy consumed by electric motors can account for up to 97% of their total lifecycle costs, depending on the application. Investing in high-efficiency drives and motors therefore usually provides a rapid return on investment. For example, the lower operating costs of WEG’sW22Xd series of IE3 explosion-proof motors can cut costs by 20–40% compared to conventional designs. WEG also has a range of IE4 (super-premium) safe area and hazardous area motors. From 2023, safe area motors from 75–200kW that are not brake motors or hazardous area motors, will have to meet IE4 requirements. n From 2021, some hazardous area motors that were previous exempt from efficiency regulations, will need to achieve minimum efficiency levels. Marek Lukaszczyk, WEG’s European and Middle East marketing manager, explains how the new requirements could deliver financial gains for users. The EU’s minimum efficiency requirements for electric motors and VSDs. The table shows the proposed scope, ambition levels and timelines, with the section outlined in red showing current measures. The asterisks (*) denote ambitions not actually covered in the text of the regulations. Electric motors used in hazardous areas such as offshore platforms will have to achieve minimum efficiencies for the first time from 2021