Is mandatory drive from 0,75 up to 375kW only IE3 from 2023 IE4

The most important facts about IE3

• In 2011, the use of IE2 motors was prescribed by law
• Since 1 January 2015 on, energy efficiency class IE3 will be mandatory for motors from 7.5 kW to 375 kW
• Since 1 January 2017 on, energy efficiency class IE3 will apply to motors from 0,75 kW to 375 kW 

Scope

For electric single speed, three-phase 50 or 50/60 Hz squirrel cage induction motor

• Rated voltage up to 1,000 V
• Rated power: 0.75 – 375 kW
• Number of poles: 2, 4, or 6
• Rated on the basis of continuous duty operation

Exceptions

• Motors completely immersed in a liquid during operation
• Motors that are fully integrated into a machine
• Brake motors
• other motor types
• Motors specially designed for operation under the following conditions:In force until 26 July 2014
  >1,000 m above sea level
  Ambient temperature > 40°C
  Ambient temperature < -15°C or respectively < 0°C with air cooling
  Cooling liquid temperatures < 5°C or > 25°CValid since 27 July 2014
  >4,000 m above sea level
  Ambient temperature > 60°C
  Ambient temperature < -30°C or respectively < 0°C with air cooling
  Cooling liquid temperatures < 0°C or > 32°C

Alternative: IE2 motor in combination with frequency converter

IE2 motors will still be permitted in conjunction with frequency converter operation, although the motor starter is always the better alternative at full speed.

Introduction: from Directive EuP to EC Motor Regulation
Directive 2009/125/EC Energy related Products – ErP (and the former version 2005/32/EC ( Eco-design Directive for Energy-using Products – EuP) establish a framework for the setting of general eco-design requirements to be fulfilled by energy-using products in view of increasing the energy efficiency of the products and the level of protection of the environment.
Within the framework of the Directive, specific Regulations have been issued for the setting of design and energy efficiency requirements, applicable to the products included in the scope of the Directive. Amongst these, Regulation 640/2009 EC establishes eco-design requirements for electric motors and their drives, in terms of energy efficiency levels.
Subject matter and scope
Regulation EC 640/2009 is applicable to electric motors, the type and size of which are defined in Article 2.1: single speed, three-phase, squirrel cage induction motors, with 2, 4 or 6 poles, rated voltage up to 1000V, rated power output between 0,75 to 375 kW (rating based on continuous duty).
Motors designed to operate wholly immersed in a liquid and motors completely integrated into a product of which the energy performance cannot be tested independently from the product (e.g. canned motor pumps), as well as motors for special applications (e.g. potentially explosive atmospheres – ATEX) are not included in the scope of the
Regulation.1
It follows that:

• submersible motors are excluded (even dry installed).
• deep well submersible motors are excluded
• motors are excluded from the Regulation if they are fully integrated into the pump unit (e.g. canned motor pump).
• motors of all designs of “close-coupled” pumps are covered by Regulation EC 640/2009. This includes motors with all types of shaft extensions and/or flanges.

New efficiency levels
Former efficiency levels were adopted by CEMEP2 as a result of a voluntary agreement based on testing methods and limits of acceptance defined under the IEC 60034-2: 1996. CEMEP efficiency levels were categorised as follows:

EFF3 = low efficiency level
EFF2 = standard efficiency level
EFF1 = high efficiency level

International efficiency levels have been defined in standard IEC 60034-30:2008, based on test methods and limits of acceptance indicated under IEC 60034-2-1:2007, as follows:

IE1 = standard efficiency (similar to EFF2)
IE2 = high efficiency (similar to EFF1)
IE3 = Premium Efficiency

These efficiency levels are listed in Annex I of the Regulation for levels IE 2 and IE 3.
Eco-design requirements and timetable
Eco-design requirements for electric motors shall be applied in accordance to the following timetable:

1. from June 16th, 2011: motors shall not be less efficient than the IE2 level;
2. from January 1st, 2015: motors with a rated output of 7,5 – 375 kW shall not be less efficient than IE3 or meet IE2, if equipped with a variable speed drive;
3. from January 1st, 2017: all motors with a rated power of 0,75 – 375 kW shall not be less efficient than IE3 or meet IE2, if equipped with a variable speed drive.

Regulation 640/2009/EC Ecodesign of Electric Motors

The ErP Directive is a framework directive and as such dictates general guidelines; its content is gradually integrated with detailed regulations to complete the general provisions. From the date the Directive came into force, implementing regulations have been and will gradually be issued that define specific standards for each product category. Among these is EC Regulation 640/2009, which lays down implementing rules for Directive 2005/32/EC of the European Parliament and of the Council on eco-design requirements for electric motors, imposing compliance with minimum energy efficiency levels and the application of new classification standards.

Regulation EC 640/2009 applies to electric motors as defined in Article 2, paragraph 1, i.e. three-phase 2, 4 and 6 pole single speed standardised motors with power ratings from 0.75 kW to 375 kW inclusive, voltage up to 1000 V and with the capacity to operate in continuous duty.
 

Ecodesign requirements

The ecodesign standards for electric motors and variable speed drives are mandatory for all manufacturers and suppliers wishing to sell their products in the EU.

Regulation (EU) 2019/1781 on electric motors and variable speed drives enters into force on 1 July 2021 and replaces the Regulation on the ecodesign of electric motors (EC) No 640/2009.

The new regulation has a broader scope and covers single-speed, 50Hz, 60Hz or 50/60Hz induction motors with the following characteristics:

• 2 to 8 poles
• single-phase/three-phase
• rated power between 0.12 kW and 1000 kW
• rated voltage from 50 V to 1000 V
• for continuous operation and direct start operation.

The energy efficiency of an electric motor is calculated as the ratio of mechanical output power to electrical input power. The energy efficiency level is expressed in international energy efficiency (IE) classes, where IE1 is the lowest class and IE5 the highest. According to the current regulation, motors must achieve efficiency level IE2, IE3 or IE4 depending on their rated power and other characteristics. For example, three-phase motors with a rated power between 0.75 kW and 1000 kW must reach the IE3 level by July 2021. Motors with a power rating between 75 kW and 200 kW must meet level IE4 as of July 2023. The EU is the first place in the world where IE4 level is mandatory for certain categories of motors.

Certain engines designed for specific conditions are excluded from these regulations, e.g. those immersed in a liquid such as in sewage systems.

The regulation also regulates the efficiency of variable speed drives. Variable speed drives have 2 efficiency levels (IE1 and IE2) and the regulation requires all variable speed drives within the scope of application to reach the IE2 level.

Both motors and variable speed drives are subject to information requirements, such as efficiency at different load points, in terms of speed and torque. This will help engineers optimise the efficiency of entire systems.

Regulation (EU) 2019/1781 was amended in 2021 by Commission Regulation (EU) 2021/341, which aims to clarify and improve certain aspects of some eco-design regulations adopted in 2019.
 

Energy savings

A more efficient engine can generate savings ranging from a few euros to several tens of thousands of euros over its lifetime, depending on its power and usage pattern.

The more efficient engines under the previous regulation are expected to lead to annual energy savings of 57 TWh in the EU by 2020. Taking into account the overall effect of the revised regulation, the annual savings will increase to 110 TWh by 2030, which is equivalent to the electricity consumption of the Netherlands. This means that 40 million tonnes of CO2 emissions per year will be avoided and the annual energy bill of EU households and industry will be reduced by approximately EUR 20 billion by 2030.

In addition, increased use of variable speed drives in relevant applications, such as a pump that provides a water flow that changes over time, can generate significant savings at the application level. This is encouraged by the regulation by requiring motor and drive manufacturers to provide relevant data on energy efficiency at different speed/torque points.
 

International collaboration

Worldwide, electric motors account for about 50 per cent of global electricity consumption. Promoting the market penetration of efficient motors and drives is an important contribution to the fight against climate change. The EU supports the Super-efficient Electric Drives and Equipment (SEAD) initiative, which brings together countries around the world to cooperate in promoting efficient equipment. SEAD currently focuses on electric motors, refrigeration, cooling and lighting, and has set the goal of doubling the efficiency of these products sold worldwide by 2030, an ambition recently welcomed by G7 ministers. New EU regulatory requirements coming into force on 1 July contribute to this goal. The EU is also a member of the International Energy Agency 4E Electric Motors Systems Annex, which aims to raise awareness of the efficiency potential of motor systems and provides guidance and tools to harness the energy performance of new and existing motor systems worldwide.
 

Documents

Regulation (EU) 2019/1781 on ecodesign requirements for electric motors and variable speed drivers
Regulation (EU) 2021/341 amending Regulations (EU) 2019/424, 1781 and 2020 to 2024
Icona application/pdfRegolamento 640/2009/CE
Icona application/pdfRegolamento 4/2014 – Modifiche al Regolamento 640/2009
Icona application/pdfLinea Guida Commissione Europea – Regolamento 640/2009
Icona application/pdfLinea Guida Assopompe – Applicazione del Regolamento 640/2009/CE
Icona application/pdfLinea Guida Europump – Regolamento 640/2009/CE
Frequently asked questions on the ecodesign measures for manufacturers and importers (April 2022)