New IE3 Requirements’ · 2019. 9. 20. · industrial controls, thanks to years of analysis and measurements of the new motor generation IE3 – premium efficiency imization We have

New IE3 Requirements’

Impact on Industrial

Motors and Controls

Are You Ready?

siemens.com/ie3ready

Restricted © Siemens AG 2016

• According to the

International

Energy agency,

electric motors

account for

approximately

45% of all

electricity usage.

Global energy consumption

by electric motors

45%

Energy consumption by electric motors


75%

Industrial energy

consumption by electric

motors

• According to the

International

Energy agency,

electric motors

account for

approximately 75%

of all industrial

electricity usage.

Energy consumption by electric motors

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwilu7fAi7fWAhWMZpoKHRSeAk8QjRwIBw&url=http://clipartbarn.com/factory-clipart_18241/&psig=AFQjCNEJLN3a8DUPiccfZzr2Hh5pnUTtVQ&ust=1506111173405862


NEMA or IEC -The new requirements are similar

History:

• In 1989, NEMA developed a standard definition for energy efficient motors.

• EPAct 1992 required that most 230V and 460V electric motors from 1 to

200HP manufactured for sale in the United States after October 24, 1997

meet minimum efficiency standards, as defined by NEMA.

• European Union (EU) Regulation 640/2009 implemented Directive

2005/EC/2005 requiring that motors, 1,000V or less, meet minimum energy

performance standards (MEPS) level IE2 by June 19, 2011

• The Energy Independence and Security Act (EISA) of 2007 requires that 230V

and 460V motors from 1 to 500HP sold in the United States after Dec. 19,

2010 meet NEMA Premium Efficiency standards

• EU Regulation 640/2009 requires motors, 1,000 or less, from 7.5kW to 375kW

meet IE3 MEPS beginning Jan. 1, 2015. Beginning January 1, 2017 the IE3

requirement is extended down to 0.75kW motors.



1997 2010 2011 2015 2017

NEMA Standard

Efficiency

IEC IE1

EPAct 1992

NEMA Energy

Efficient Motors

European Union

(EU) Regulation

640/2009 IE2

Motors

EISA 2007

NEMA Premium

Efficiency Motors

European Union

(EU) Regulation

640/2009 IE3

Motors 7.5 –

375kW European Union

(EU) Regulation

640/2009 IE3

Motors 0.75 –

375kW


Potential energy savings

• Premium efficiency and IE3 compliant motors should be specified

in the following instances:

• New installations

• When making major modifications to existing facilities or processes

• For all new purchases of OEM products

• Purchasing spares

• In lieu of rewinding standard or high efficiency motors

• To replace oversized motors (when motor is operating at less than

40% of its rated load

• When replacing existing standard or high efficiency motors


0

20

40

60

80

100

120

Life Cycle cost of anElectric Motor

Motor Purchase cost 3%

Energy Consumed 97%

Potential savings


• 85% of electric motors are

15kW (20HP) or smaller.

(More than 50% are 3.75kW

(5HP) and smaller).

• Based on normal operating

hours, 15kW (20HP) and

smaller motors constitute 15%

of electric motor energy

consumption.

• Therefore, the greatest

potential energy savings is on

the larger motors.


• Smaller motors are typically less efficient than larger motors

• The smaller the motor, the greater percent efficiency

improvement. As the motor size (kW or HP) increases, the

efficiency gain (in percent) diminishes.

15kW (20HP)


IEC Motor Efficiency

NEMA Motor Efficiency

7.5kW

150kW

10HP

200HP




(7.5kW)

(18.75kW)

(37.5kW)

(56.25kW)

(75kW)

(122.5kW)

(150kW)

Typical Annual Value of a 1% Gain in Motor Efficiency ($0.08 per KWH)


What makes a motor premium efficient

or IE3 compliant?

Electric motor components that can be

modified to increase motor efficiency

Bearings

Rotor

Stator Windings

Air Gap

Stator Laminations

End Rings

Fan

Changes to the Stator Windings

and Laminations, and the Rotor

necessitate making the motor

longer. Due to motor standard

designs, the relationship

between mounting and output

shaft are kept the same.


What makes a motor premium efficient

or IE3 compliant?

Standard Efficiency

Energy Efficient Premium Efficiency

All 3 motors have the same HP ratings



The official

adoption date

of the new law

for IE3 motors

began in 2015!



2017

0.75

The official

adoption date

of the new law

for IE3 motors

began in

2015!

In 2017, it

expanded to

include

smaller

motors.


EU Regulations 640/2009 and 04/2014

define the scope

10.2016 Page 17

Exception:

IE2 + frequency converter remain valid at first,

although a motorstarter is the better alternative at

full speed

Regulation (EG) 640/2009 - 04/2014:

For AC squirrel cage motor 50 Hz or 50/60

Hz:

• rated voltage: up to 1000 V

• power rating: 0,75 – 375 kW

• number of poles: 2,4 or 6

• continuously rated

Valid until 26th of Juli 2014 (640/2009) Valid after 27th of Juli 2014 (04/2014)

> 1000 m above sea level > 4000 m above sea level

Ambient temperature > 40 °C Ambient temperature > 60°C

Ambient temperature < -15°C or < 0°C water-cooled Ambient temperature < -30°C or < 0°C water-cooled

Coolant temperature < 5°C or > 25 °C Coolant temperature < 0°C or > 32 °C

exception:

• Motors in operation fully covered in liquid

• Fully integrated motors in machines (e.g. fan)

• Brake motors

• Other types of motors that are constructed especially for operating under

the following parameters (table below)

Scope EU Regulation

Introduction of the EU Regulation

• in 2011 IE2 motors were set as standard

• after 01.01.2015

IE3 motors from 7,5 kW to 375 kW

• after 01.01.2017

IE3 motors from 0,75 kW to 375 kW


10.2016 Page 18

IE3 and Premium efficiency motors behave differently

What does this mean for control and

protective devices?


IE3 motors are different, compared to IE2 motors

– the results of 4 years of motor analysis

10.2016 Page 19

Challenges

► Decreasing nominal current at same power

► Ratio Ia/In is increasing

► Inrush current is increasing

What is changing from IE1/IE2 to IE3?

Impact of IE3 motors

►Inrush current is not published by the motor

manufacturers, and it is unknown to them

►The ratio Ia/In and the inrush current differ for

every motor

the data varies greatly

Starting behavior of an IE3 motor

Within the last 4 years, Siemens analyzed more

than five thousand motors, based on data

Based on own measurement of IE3 motors of

different manufacturer the validation of the

Inrush-current was possible


The critical factors are partially reduced

by the application

10.2016 Page 20

Measurement of IE3 motors in worst case conditions – electrical network with high short circuit

power, minimum conductor length, adverse activation angle

Electrical network with low

short circuit power

Conductor length

Activation angle

Cave in of the voltage

Line impedance (inductance)

increases

Activation close to the zero

means less voltage

Impact of the application Attenuation of the current

Attenuation of the current by the application


The increasing inrush current is the biggest

challenge for Industrial Controls

10.2016 Page 21

Lower nominal current

Increasing starting current

Increasing inrush current

Impact on devices with overload and short

circuit protection

Impact on devices with limitations of

maximum current during start-up

(e.g. solid state devices)

Impact on switching capacity and breaking

capacity of the devices

Changes with IE3 Impact on industrial controls


10.2016 Page 22


We are IE3ready!

10.2016 Page 23

An

aly

sis

We know all the requirements of the new IE3-motors for our

industrial controls, thanks to years of analysis and

measurements of the new motor generation IE3 – premium

efficiency

Op

tim

izati

on

We have optimized our SIRIUS industrial controls for those new

requirements, e.g. our new MSP 3RV2 size S2 with adapted

tripping behavior, extended setting ranges and increased

switching capacity

IE3 r

ea

dy!

We are IE3 ready!

Reliable switching and protection of motors at any time – for

IE1, IE2 and IE3


Circuit breaker, contactor, motorstarter

– our devices are IE3ready

10.2016 Page 24 Stein, Gregor / DF CP S&MK MP 1

Jeffrey Woolfolk

E-Mail:

[email protected]

siemens.com/ie3ready
mailto:[email protected]

Documents

New IE3 Requirements’ · 2019. 9. 20. · industrial controls, thanks to years of analysis and measurements of the new motor generation IE3 – premium efficiency imization We have