WP5 T2 High Efficiency EM Standards JSI Slovenia

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European Commiss ion (Directorate-General for Energy and Transport)Contract no. NNE5/2002/52: OPET CHP/DH Cluster

Project Title:

OPET CHP/DHC

Work Package 5 Task 2

Promotion of high efficiency electric motors in Europe

Deliverable No. D8-a

DEFINITION OF STANDARDS FOR HIGH

EFFICIENCY ELECTRIC MOTORS

May 2004


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The project "OPET CHP/DH Cluster" has obtained financial support from the EuropeanCommission (Directorate-General for Energy and Transport) under the contract no. NNE5/2002/52for Community Activities in the Field of the specific programme for RTD and demonstration on"Energy, Environment and Sustainable Development - Part B: Energy programme"

The responsibility for the content on this publication lies solely with the authors. The content doesnot necessarily represent the opinion of the European Community and the Community is notresponsible for any use that might be made of data appearing herein.

Definit ion of Standards for High Efficiency Electic Motors

Author(s): Toma FaturOrganisation: J ozef Stefan Institute - Energy Efficiency Centre (EEC)Address: J amova 39, SI-1000 Ljubljana, SloveniaTel.: +386 (0)1 588 52 10Fax: +386 (0)1 561 23 35

E-mail: [email protected]: http://www.rcp.ijs.si/~eec/


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OPET CHP/DHC Work Package 5 Task 2 Definition of Standards for HEEM Page 3 of 13

Contents

1. INTRODUCTION.....................................................................................................4

2. EU MOTOR EFFICIENCY CLASSIFICATION SCHEME .......................................5

3. ONGOING PROGRAMMES ...................................................................................6

4. EU MOTOR CHALLENGE PROGRAMME.............................................................8

4.1 MOTOR CHALLENGETOLLS 9

5. CONCLUSIONS AND RECOMMENDATIONS.....................................................10

5.1 CRITICAL SUCCESS FACTORS 11

6. LITERATURE .......................................................................................................13


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1. INTRODUCTION

In recent years, many motor manufacturers have invested heavily in R&D and newproduction facilities to bring to market motors that have higher efficiency, but with littleincrease in price. This new generation of motors look and perform in a very similar wayto standard efficiency motors, but have significantly lower running costs. Through manysmall changes in the detail of the design, improved materials and close attention toassembly procedures, this improvement in efficiency can be equivalent to a reduction inenergy losses of 25%.

Other benefits of using Higher Efficiency Motors include:

increased reliability through: more and better materials lower heat generation longer insulation and bearing life less vibration

less noise improved power factor

In the past it was always very confusing trying to work out just what is a HEM, withdifferent manufacturers all claiming to offer "energy efficient" motors. The EU is alsoworking with CEMEP, the European Committee of Manufacturers of Electrical Machines

and Power Electronics, to improve the efficiency of motors. In 1996, the EUCommission unveiled its plans to expand the use of high-efficiency motors, and CEMEPwas instructed to work towards making these motors standard.

European Commission and EU motor manufacturers have agreed on the EU/CEMEPmotor efficiency classification scheme. There are three class levels of efficiency, knownas Eff1, Eff2 and Eff3, applying to low voltage two- and four-pole motors with ratingsbetween 1.1 and 90 kW .

All manufacturers who have signed the agreement between the European Commissionand CEMEP are able to display an Efficiency logo on their motors, making it easy toidentify the class of motor. This can be seen in catalogues, advertising, and on motorsthemselves. In addition, it should not be forgotten to check what motors are suppliedwith any purchased OEM equipment.

The scheme requires motor manufacturers literature to indicate the Class Level atthree-quarter and full load. The motor nameplate also needs to carry confirmation of theClass Level. The programme was implemented by a voluntary agreement between theCommission and the motor manufacturers to reduce sales of EFF3 motors by half by2003, a target which has been reached, and zero sales are to be obtained soonafterwards, at the same time increasing the numbers of motors made in levels Eff1 and


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Eff2. The scheme will also encourage motor users to use high-efficiency motorsexclusively.

2. EU MOTOR EFFICIENCY CLASSIFICATION SCHEME

European Commission and EU motor manufacturers have agreed on the EU/CEMEPmotor efficiency classification scheme. There are three class levels of efficiency, knownas Eff1, Eff2 and Eff3, applying to low voltage two- and four-pole motors with ratingsbetween 1.1 and 90 kW .

Figure 1: Efficiency classes (Class 1 = Eff 1, Class 2 = Eff 2, Class 3 = Eff 3

The motors included in this scheme are defined as totally enclosed fan ventilated(normally IP 54 or IP55), three phase A.C. squirrel cage induction motors 1.1 to 90kW,with 2- or 4-poles, rated for 400V line, 50Hz, S1, duty class, in standard design.(Standard design can be interpreted as Design N according to EN 600 34-12 and HD231).

Figure 2: Efficiency label marks Eff 1 means highest efficiency

Motors are labeled according to above efficiency classes. Eff3 represents all motorsbelow the minimum class Eff2 standard. Motors carrying the Eff 1 logo, it shows that it isin the highest class, give the very lowest in running costs.


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kW

EFF 3

2- & 4-polen [%]

EFF 2

2- in 4- polen [%]

EFF 1

2- polen [%]EFF 1

4- polen [%]1,1 < 76,2 76,2 82,2 83,81,5 < 78,5 78,5 84,1 85,02,2 < 81,0 81,0 85,6 86,43 < 82,6 82,6 86,7 87,44 < 84,2 84,2 87,6 88,3

5,5 < 85,7 85,7 88,6 89,37,5 < 87,0 87,0 89,5 90,111 < 88,4 88,4 90,5 91,015 < 89,4 89,4 91,3 91,8

18,5 < 90,0 90,0 91,8 92,222 < 90,5 90,5 92,2 92,630 < 91,4 91,4 92,9 93,237 < 92,0 92,0 93,3 93,645 < 92,5 92,5 93,7 93,955 < 93,0 93,0 94,0 94,275 < 93,6 93,6 94,6 94,790 < 93,9 93,9 95,0 95,0

Figure 3: Efficiencies of individual classes

3. ONGOING PROGRAMMES

Regulation is needed on minimum efficiency performance standards for different partsof motor systems. Actually, so far, only motors have been addressed. To realise thesavings potential in motor systems energy audits are essential, but they need to besupported by a regulatory framework of periodic inspections. Such inspections can

cover all energy systems at a plant. In order to maintain quality, inspectors need to betrained and, where necessary, certified. Information and promotion need to work inparallel, in order to train users to comply with the requirements of any new regulations.

Test cases need to be developed in the market, preferably with industry leaders, todemonstrate the benefits of high efficiency motor systems. Often, lack of capital is abarrier, and needs to be addressed by financial schemes, such as performancecontracting or tax incentives.

A number of programmes for promoting enhanced motor system efficiency have beeninitiated in the European Union and the United States. They each concentrate on certaintypes of activities. These programmes are:


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The European Motor Challenge Programme a voluntary programme instituted bythe European Commission to improve the efficiency of motor driven systems

France - 1977 Energy saving decree requires mandatory energy inspection inindustry

Italy - 2001 Energy efficiency decree - linked to liberalisation, it requires distributionutilities to implement an energy saving programme with quantified, progressiveannual targets

Sparemotor - The Danish government gave subsidies for high efficiency motors aspart of a larger campaign

EU motor efficiency labels - devised by the European Committee of Manufacturers

of Electrical Machines and Power Electronics, and the European Commission

US EPAct - the Energy Policy Act describes the minimum standards for energyefficient motors

US NEMA Premium - the National Electrical Manufacturers Association labels highefficiency motors.

Figure 4: Energy efficient fans for tunnel ventilation


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4. EU MOTOR CHALLENGE PROGRAMME

The Motor Challenge Programme is a European Commission initiative to aid industrialcompanies in improving the energy efficiency of their electric Motor Driven Systems.

The Challenge focuses on Compressed Air, Fan and Pump systems, for which it hasbeen demonstrated that there exists a large technical and economic potential for energysavings.

Any enterprise planning to contribute to the Motor Challenge Programme objectives

can participate:

Companies that use Motor Driven Systems can request "Partner" status.

Companies that supply Motor Driven Systems may become "Endorsers".

Partners will be aided in reducing operating expenses, through profitable, costeffective measures. Furthermore, they will receive public recognition for theircontribution to achieving the objectives of the European Union's energy policy:

minimising environmental impact, and in particular reducing CO2 emissions;

improving the competitivity of European industry;

reducing dependence on imported energy sources.

The core of the programme is anAction Plan, by which a Challenge Partner commitsto undertaking specific measures to reduce energy consumption. The Partner companydetermines which production sites, and which types of systems, are covered by thecommitment. The scope of the commitment is flexible, and can be limited to a singleshop, or may include all of the company's European production sites.

Challenge Partners will receive aid, advice and technical assistance from theCommission and from participating National Energy Agencies in formulating and

carrying out their Action Plan. Companies should be able to:

maintain or improve both the Reliability and the Quality of Service of the systemsconcerned;

realise the major portion of technically and economically feasible energy savings.

Furthermore, companies will receive public recognition for their efforts, through theProgramme's promotion campaign:


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Partners may use and post the Motor Challenge Programme logo, thus publicisingtheir energy saving actions and their contribution to the environment.

The list of Challenge Partners, including a description of their specific contribution tothe Programme will be published widely (brochure, Internet, etc.).

Partners will be invited to provide documentation of a showcase installation that theEuropean Commission can publicise.

The enterprise's relevant activities may be included in Challenge promotionalactivities, such as Awards and the Catalogue.

Challenge Programme Awards will be made to outstanding Motor ChallengePartnerships in several categories.

Suppliers of equipment and services related to Motor Driven Systems may participate inpromoting the Motor Challenge, for instance by assisting Partners in defining andcarrying out their Action Plan. Such companies are encouraged to register as MotorChallenge Endorsers. Endorsers get public acknowledgement for their efforts to supportthe Motor Challenge Programme.

The Motor Challenge Programme is totally voluntary: companies are free to decidewhether they want to join or not, and they may withdraw from the programme at anytime without any prejudice.

Motor Challenge benefits from the active support of the National Energy Agencies of 15European countries. For further information these should be addressed or PaoloBertoldi [email protected] at the European Commission; web page:http://energyefficiency.jrc.cec.eu.int/motorchallenge/index.htm.

Figure 5: MotorChallenge logo

4.1 Motor Challenge Tolls

Different tolls are available in the scope of Motor Challenge Programme:


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EuroDEEM

The European database for motor systems, EuroDEEM, contains high efficiency electricmotor data. It is an important information tool that allows users to select the mostenergy-efficient electric motor for a new installation or for a replacement, evaluatingenergy and financial savings. In this respect, EuroDEEM helps promote electricitysavings. EuroDEEM Web Site: http://energyefficiency.jrc.cec.eu.int/eurodeem/index.htm

European Motor Classification Scheme

This scheme facilitate the identification of high efficiency motor (motor in efficiency classEFF 1), and standard efficiency motors (class EFF 2). PDF files (about 215 Kb): [En][Es] [De] [It] [Fr].

European Guide to Pump Selection and the Basic on Pump Efficiency

This Guide help end-users to select the most efficient pump for a give duty. Thedocument Basic on Pump Efficiency provides simple and clear information to introduceend users to pump efficiency. Pdf files: [Guide 136 Kb] [Efficiency 179 Kb]

Tips for assessing profitability

To know how to calculate profitability, visit the page "Economics".

Catalog of information resources

Using a keyword, this catalog indicates the corresponding resources listed in the EU.These resources are about written documents, training courses, Web-sites, etc. Theyare indicated for countries and languages. The list is not exhaustive. Catalog in Excel[XLS file 153 Kb]

Energy Service Companies (ESCO)

ESCOs provide comprehensive energy efficiency services to consumers includingproject finance, engineering, project management, equipment maintenance monitoring

and evaluation, usually through Energy Performance Contracts (EPC). List of EuropeanEnergy Service Companies available.

European Studies on motor system components

Second motor study file [PDF file 1.5 Mb]; VSD save study [PDF file 1.9 Mb]; Savepump report [PDF file 1.5 Mb].

5. CONCLUSIONS AND RECOMMENDATIONS

Importance of establishing an agreement over what exactly constitutes a high efficiency

motor system IS NEEDED for each EU countries. A first step in achieving agreement is


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to define efficiency levels. When these levels have been established, motors can thenbe officially classified and labelled. This phase has already been accomplished for

the motors themselves. The EU/CEMEP system divides motors into three welldefinedclasses: EFF3, EFF2 and EFF1 (EFF1 being the highest efficiency). It is important tonote that energy efficiency standards, whether they are voluntary or regulated, shouldnot be seen as fixed, but rather as something constantly being re-evaluated todetermine the right time to increase it to a higher level. Experience has shown thatEFF3 motors are now a negligible fraction of the market, but the same is true for theEFF1 motors. In other words, the voluntary scheme has moved the market focus ontoEFF2 motors. To move the market to EFF1 motors, and allow the huge cost-effectiveenergy savings to be tapped, there may be a need to impose mandatory minimumefficiency standards.

For the complete motor system, such labelling is often difficult. This is because theefficiency levels of those systems not only depend on the machines purchased, but justas much on the method of installation and operation. A possible way to ensure energyefficiency could be to:

recommend best practice for motor system efficiency in the IPPC operating licencefor industrial sites

implement a mandatory auditing scheme, currently foreseen in the draft directiveon energy services.

ISO 14001 and EMAS accredited companies can be an interesting target for motor

system efficiency improvement. Such efficiency improvements can be reported as animprovement in the company's environmental performance.

The IPPC directive requires industrial installations falling under it to apply bestavailable technology for energy efficiency, among other things. This includes highefficiency in motor driven systems.

5.1 Critical success factors

From the programmes described above, several conclusions can be drawn. These are afew of the critical success factors for every programme that aims to promote highefficiency motor systems in Europe:

1. A legal framework

2. Adequate support

3. High quality information, in relevant terms

4. Streamlined with other programmes

5. Measuring results and giving feedback


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6. Involvement and co-ordination between different interested parties

7. Differentiating for each separate market.

Energy efficiency labelling has the same role as other labelling schemes which wereagreed on the EU level many years ago, but had many problems for implementing. Thisis overcome through CEMEP/EU and now further steps have to be taken. MotorChallenge programme is next step but voluntary schemes have not been proven in newEU countries and also lack of credible studies are available for new countries.

A promising role can be expected from new energy services directive (requesting 1%energy savings from member states) and environmental driven measures and activities

(incl. EMS, ISO 14001, IPPC). Electric motors as largest electricity consumer has toplay its role also in DSM programmes, which are crucial for ensure security of energysupply in EU, a challenge for next years.


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6. LITERATURE

Energy Efficient Motor Driven Systems, European Copper Institute, April 2004

http://energyefficiency.jrc.cec.eu.int/motorchallenge/

http://motors.copperwire.org/

http://www.abb.com/motors&drives

WP5 T2 High Efficiency EM Standards JSI Slovenia

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