Controlling High Efficiency Motors

Components for IE3 Motors:

Circuit Breakers
Contactors
Starters
Overload Relays
Load Switches
Smart Motor Controllers
Solid-State Contactors
CONTROLLING HIGH EFFICIENCY MOTORS

Introduction
Over the last decade, significant efforts have been invested in
developing standards and regulations to protect the environment,
limit our carbon footprint and reduce energy consumption.
With Directive 2009/125/EC, the European Union has established a framework
for the integration of environmental aspects into product design. Ecodesign
regulations for individual product groups then require manufacturers to reduce
the energy consumption of their products by establishing minimum energy
efficiency requirements.

New regulations for energy efficiency.

Electric motors are accountable for almost 50 % of This regulation specifies that
the electricity consumption in Europe and for 60 • From 16 June 2011, motors shall not be less
to 70 % of the electrical energy consumption in efficient than the IE2 efficiency level.
the industry. For this reason, electric motors were
• From 1 January 2015, motors with a rated output
one of the first product groups to be subject to
of 7,5-375 kW shall not be less efficient than the IE3
mandatory energy efficiency requirements under
efficiency level or meet the IE2 efficiency level and
the EU Ecodesign Directive. According to the
be equipped with a variable speed drive.
European Commission, Europe could save around
135 TWh of electricity by 2020 – equivalent to the • From 1 January 2017, all motors with a rated
annual electricity consumption of Sweden – if output of 0,75-375 kW shall not be less efficient
higher efficiency motors were to be utilised. This than the IE3 efficiency level or meet the IE2
would mean that over 60 million tonnes of CO2 efficiency level and be equipped with a variable
emissions would be avoided. speed drive.
(Source: European Commission - Energy)
The efficiency levels are specified in the Regulation
Commission Regulation (EC) 640/2009 (as and are equivalent to the following efficiency
amended by Commission Regulation (EU) 4/2014) classes as defined in harmonized standard EN
sets mandatory efficiency requirements for 2- to 60034-30:
6-pole, single speed, three-phase squirrel cage IE1: Standard efficiency
induction motors rated up to IE2: High efficiency
1000 V, with a power range of 0.75 KW to 375 kW,
IE3: Premium efficiency
and on the basis of continuous duty operation.
Market in evolution
According to a study from IHS, the motor market continues to grow at a rate of about
5% per year, and the migration from IE1 motors towards the more efficient types IE2
and IE3 is happening rapidly. Other parts of the world also are going through a similar
process, making this evolution a worldwide development.
Typical Inrush Current
, inrush / ,e Effciency classes IE1, IE2, IE3
The World Market for Low Voltage Motors
15.00
Units (k) IE1, IE2, IE3 Unit Shipments: 2009…2018
40'000 14.00
EU starts IE1 Motors
IE2 shift
13.00 IE2 Motors
35'000
IE3 Motors
12.00
China starts
30'000 Brazil starts
IE2 shift IE2 shift
11.00
25'000 EU (phase 3)
10.00 & Japan starts
20'000 EU (phase 2) IE3 shift
& Japan starts
9.00
IE3 shift
15'000 Canada starts
US starts IE3/NEMA
8.00
IE3/NEMA PremiumTM shift
10'000 PremiumTM shift
7.00
2 20 200
5'000 IE1 Motors
Inrush Current [kW]
IE2 Motors
IE3 Motors
0
2009 2010 2011 2012 2013 2014 2015 2016 2017 2018

Source: IHS, Motor Market Update, Motor summit 2014, Zurich/October 2014

IE3 motor or IE2 with AC Drives

Regulation 640/2009 does still allow IE2 motors to be used when controlled by a
variable speed drive. However, whilst there are some applications in which variable
speed drives (VSD) are the better alternative, it is also clear that motor starters offer
often the most energy efficient solution for fixed speed applications independently
from the efficiency class of the motor (IE2/IE3).
Other advantages of motor starters (such as direct-on-line starters, Star Delta starters
or soft starters) include:
• Optimal control cabinet design (reduced need for additional
cooling and thus lower energy consumption)
• Simple implementation
• Robust motor system
• Lower cost (affordable price, simple installation, operation & maintenance)
As a consequence, for fixed speed applications, traditional motor starters are often
the most preferred solution.
 How do IE3 motors differ
from lower efficiency motors?
Even if their rated current is lower, higher efficiency motors have a higher inrush current
and an increased starting current compared with motors of lower efficiency classes.
This behavior can generate nuisance trips or other undesirable effects during starting and
needs to be carefully considered when selecting components for IE3 motor applications.
I / Ie

15

Inrush current
10

Starting current

Motor rated current

0

-5

-10

In the picture above, which shows the typical starting phase of an

induction motor, three levels of current can be noticed:
• The inrush current with a very high value during the first half cycle.
In IE3 motors this value is noticeably higher than in other classes
of motor because of the additional saturation effect around the
windings which is in turn caused by lower stator resistances.
• The inrush current is followed for a certain period of time by what
is normally defined as `starting current’ with a value several times
greater than the rated current.
• Finally, the motor progressively reaches its nominal
current value, defined as motor rated current.
 Typical Starting Current Typical Inrush Current
Effciency classes IE1, IE2, IE3 , inrush / ,e Effciency classes IE1, IE2, IE3
,s / ,e
8.00 15.00

14.00
7.50
13.00

7.00
12.00

6.50 11.00

10.00
6.00
9.00

5.50
8.00

5.00 7.00
2 20 200
2 20 200 IE1 Motors
IE1 Motors Inrush Current [kW]
DOL Current [kW] IE2 Motors
IE2 Motors
IE3 Motors
IE3 Motors

The specific starting current characteristics of the higher efficiency motors are requiring a special attention.
A proper selection of the motor starting and switching components will make sure that the application starts
without disturbances nor component damages. In particular, the following risks exist and must be avoided:
• Motor Protection Circuit Breaker& Molded Case • Solid State Contactors – additional heating and
Circuit Breakers – risk of nuisance tripping on start potential tripping (Thyristors Overtemperature)
especially on high duty cycle applications
• Contactors – potential tack welding on start
• Soft Starters – additional heating and potential
• Overloads – nuisance tripping on Overload
tripping (Thyristors Overtemperature or Overload)
especially on high duty cycle applications
especially on high duty cycle applications

Conclusion
The recent evolution of the regulations for Energy- the devices can be reduced. If a majority of motor
related Products requires machine builders and starting equipment can still be used with the new
engineering companies to use modern energy- IE3 motors, care must be taken that their limits are
efficient motors. The electric characteristics of respected. Electric equipment manufacturers are
these motors present some challenges to the issuing corresponding guidelines and designers
manufacturers of motor starting devices. of motor systems must verify the compatibility of
motor and starter in their specific applications.
Due to the higher current drawn by the motors
during the starting phase, nuisance tripping can
occur, contacts can be damaged and the life of
Rockwell Automation
offers a broad portfolio of
motor starter components
that are compatible with
IE3 motors.

Description • Motor Protection • Molded Case • Contactors • Motor Starters • Bimetal Thermal
Circuit Breaker Circuit Breakers Overload Relay
• Molded Case
Motor Circuit
Protector
• Molded Case
Motor Protection
Circuit Breakers

Bulletin 140M-C 140G 100-K 190-S, 191-S 193-K

number 140M-D 140MG 100-C 190-E, 191-E 193-T1
140M-F 140MG 100-D
100-G 103, 105, 107, 109

Current 0.16...2.5 A 15...3000 A 5...12 A 0.1...45 A 0.1...12.5 A

range 2.5...32 A 3...1200 A 9...97 A 0.1...25 A 0.1...90 A
25...45 A 25...150 A 115...860 A
550...1200 A
Description • Electronic • Control and Load • Solid-State • Soft Starters • AC Drives
Overload Relay Switches Contactors

Bulletin 193-ED 194E 156-B 150-C All PowerFlex

number 193-EE 194R 150-F AC drives
193-EC 194L 150-S
193-ESM

Current 0.1...45 A 16…100 A 20…32 A 3…480 A 0.2 kW…1.5 MW

range 0.1...800 A 30…800 A 5…1250 A
0.4...5000 A 12…40 A 90…520 A
0.5...200 A
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Publication IE3-BR001A-EN-P - November 2015 Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.