1. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 1 EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with reference to market surveillance Enzo Chiricozzi Edoardo Fiorucci Dept. of Industrial and Information Engineering and Economics University of L’Aquila, Italy Coiltech – September, 24-25 2014 Pordenone

2. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 2 Outline of the presentation 1.Introduction 2.Efficiency levels 3.The IE-Code 4.Measurements and calculations 5.Experimental results 6.A proposal for a certified laboratory 7.Conclusions

3. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 3 Outline of the presentation 1.Introduction 2.Efficiency levels 3.The IE-Code 4.Measurements and calculations 5.Experimental results 6.A proposal for a certified laboratory 7.Conclusions

4. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 4 1. Introduction  The efficiency values of induction motors have heavy effects on the energy consumptions in industrial application*; the efficiency of these motors can be successfully increased up to 20-30%, as proved by recent studies.  In recent year, several international standards and regulations have been published, with the aim of introducing new efficiency classes and determining high accuracy procedures for the experimental measurement of motors efficiency.  Nevertheless, in the complex scenario created by all these documents, some issues concerning the experimental uncertainty and its interpretation in the efficiency measurement can be raised.

5. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 5 1. Introduction  In this presentation, an analysis of this important topic is proposed, supported by experimental results.  A proposal for a certified laboratory for high accuracy efficiency measurement of induction motors is also presented.

6. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 6 Outline of the presentation 1.Introduction 2.Efficiency levels 3.The IE-Code 4.Measurements and calculations 5.Experimental results 6.A proposal for a certified laboratory 7.Conclusions

7. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 7 2. Efficiency levels  In 2009, the European Commission published a new regulation (n. 640/2009) concerning requirements for the eco- compatible design of electric motors;  in detail this regulation applies to single speed, three-phase 50 Hz or 50/60 Hz, squirrel cage induction motor, with 2-, 4- and 6- poles, rated voltage up to 1000 V, rated output power between 0,75 kW and 375 kW, continuous duty operation.

8. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 8 2. Efficiency levels  Two levels of efficiency are proposed: i.IE2 – high efficiency, that is equivalent both to Eff1 and to U.S. EPAct for 60 Hz; ii.IE3 – premium efficiency, that is a new level for the European market, and is equivalent to NEMA Premium for 60 Hz. From 2013 the newly revised Efficiency Classification in IEC 60034-30-1 also include motors from 0,12 kW to 1000 kW, with 2-,4-,6- and 8-poles and will go up to the new efficiency class IE4 Super Premium Efficiency.

9. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 9 2. Efficiency levels  In the Eurozone the following timetable has been defined and will be mandatory: - from January 1 st 2015 all the motors with rated power between 7,5 and 375 kW must comply to IE3 efficiency, otherwise IE2 if equipped with a variable speed drive; - from January 1 st 2017 all the motors with rated power between 0,75 and 375 kW must comply to IE3 efficiency, otherwise IE2 if equipped with a variable speed drive*.  It is estimated that this measure will save 135 Twh per year in 2020.

10. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 10 2. Efficiency levels  In such an interesting scenario, the synergies between universities and manufactures could lead to an effective development of the high efficiency motors market, with the aim of experimentally verifying if the required performance has been satisfied or not.  One of the most critical aspects about the monitoring, verification and watch of the market is the development of an independent laboratory (as required by EC regulation n. 640/2009) for the motor testing and measurements for such a wide range of rated power values, between 0,75 and 375 kW, and poles numbers, between 2 and 6.

11. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 11 Outline of the presentation 1.Introduction 2.Efficiency levels 3.The IE-Code 4.Measurements and calculations 5.Experimental results 6.A proposal for a certified laboratory 7.Conclusions

12. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 12 3. The IE-Code  The new edition of IEC 60034-2-1 (Standard methods for determining losses and efficiency from tests) continues to make good progress, having been discussed recently at meetings in Washington (2011), Kyoto (2012) and Instanbul (2013). The testing method in the revised IEC 60034-2-1 is clarified and defined as the “Preferred Method “*.  Important improvements include the specification of a single preferred method for the measurement of induction machine efficiency, and a specified temperature range for ambient air temperatures.  Yet to be finalized is the question of specifications for measuring instruments and the expected uncertainty associated with final efficiency figures produced using the specified measurement methods.

13. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 13 3. The IE-Code  The first edition of IEC 60034-30 is limited to three-phase cage-induction motors; the second edition will cover all types of motors (fixed and variable speed) that are used in industrial applications within the specified output power range.  The IE classes IE1 to IE4 for 50Hz and for 60Hz is published in IEC 60034-30 Part 1 and for variable speed motors in Part 2.  IE3 Premium efficiency are now mandatory in North America, and will be mandatory in the EU by 2015.

14. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 14 3. The IE-Code  Motors of IE4 Super-Premium Efficiency class are already available in the market since 2010; within this class Line-Start Permanent Magnet Motors (LSPM) are a recent entrance in the industrial motor market.  Of late the EU requested a new Ultra-Premium Efficiency class: IE5 in their mandate; as of the time of writing, no motor products beyond IE4 are known in the market place and consequently a useful definition of IE5 cannot be given.  It is envisaged that the losses of IE4 motors will be reduced further by some 20% for the IE5 class.

15. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 15 Outline of the presentation 1.Introduction 2.Efficiency levels 3.The IE-Code 4.Measurements and calculations 5.Experimental results 6.A proposal for a certified laboratory 7.Conclusions

16. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 16 4. Measurements and calculations  In the Annex II of EC Regulation N.640/2009 it is said: “For the purpose of compliance and verification of compliance with the requirements of the Regulation, measurements and calculations shall be made using a reliable accurate and reproducible method, which takes into account the generally recognized state-of-the-art methods, and whose results are deemed to be of low uncertainty..”

17. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 17 4. Measurements and calculations  By considering the procedures of IEC 60034-2-1, really some technical concerns about the overall accuracy of the efficiency measurement methods proposed can be raised, especially for the evaluation of additional load losses, that can be critical if we consider that high efficiency values are to be measured.  In this scenario, the JCGM 100:2008 Evaluation of measurement data — Guide to the expression of uncertainty in measurement is fully applicable.  The introduction of procedures for measuring the performance of induction motors mentioned above will necessarily entail legal metrology implications; efficiency measurements carried out in different laboratories with different instruments will provide results whose compatibility should be assessed.

18. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 18 4. Measurements and calculations  Furthermore, the accepted uncertainty in the power losses measurement can be up to 15%, for induction motors on power range 0,75-150 kW, and 10% on power range >150-375 kW, by introducing a further element of potential disagreement in defining the exact level of efficiency of an induction motor in the IE classification, as stated in EC Regulation N. 640/2009, Annex III

19. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 19 4. Measurements and calculations Fig.1 - IEC 60034-30-1 efficiency curves for 2 poles induction motors  The fig.1 shows the efficiency curves defined in IEC 60034-30-1 for 2 poles induction motors. The difference between the IE1 and IE2 curve is in the range 5.3-1.0%, while the difference between IE2 and IE3 curve is in the range 3.3-0.8%.

20. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 20 4. Measurements and calculations  For understanding the potential disagreement in evaluating the efficiency of an induction motor due to this high uncertainty, each curve in Fig.1 should be replaced by a set of two curves, obtained by considering respectively ±15 % (induction motors for rated power up to and including 150 kW) and ±10% (induction motors for rated power above 150 kW) increment and decrement of the losses related to the IE efficiencies defined by IEC 60034-30-1, according to the rate power. The obtained six curves are in Fig. 2.

21. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 21 4. Measurements and calculations Fig.2- IEC 60034-30-1 efficiency curves for 2 poles induction motors, with the effects of +/-(15/10) % uncertainty in power losses measurement.

22. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 22 4. Measurements and calculations  As a first remark, there are some overlaps, because the IE2+(15/10)% curve is lower than IE1-(15/10)% curve, and the IE3+(15/10)% curve is lower than IE2-(15/10)% curve. This issue could involve some difficulties in classifying an induction motor and can be cleared with the following example*: 5 kW, 2poles Induction motor IE1 IE2 ±15% of the losses

23. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 23 4. Measurements and calculations  A second remark concerns the possibility for the motor manufacturers to take advantage of this uncertainty, by classifying lower efficiency motors as in compliance with IE classification.  To harmonize EC Regulation N. 640/2009, Annex III with the IE efficiency classification from the measurement point of view, a lower accepted uncertainty in power losses measurement should be defined to avoid the described overlapping.  As a suggested value, 5.5 % is the maximum for the uncertainty in power losses measurement to avoid overlapping, as shown in Fig. 3.  By introducing this lower uncertainty, the classification of a tested induction motor can be univocal.

24. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 24 4. Measurements and calculations Fig.3 - IEC 60034-30-1 efficiency curves for 2 poles induction motors, with the effects of the suggested +/-5.5% uncertainty in power losses measurement.

25. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 25 Outline of the presentation 1.Introduction 2.Efficiency levels 3.The IE-Code 4.Measurements and calculations 5.Experimental results 6.A proposal for a certified laboratory 7.Conclusions

26. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 26 5. Experimental results  In our laboratories at the University of L’Aquila, we have been testing several induction motors whose rated power is up to 15 kW *, both for research and industrial applications, since 1994.  In the following some experimental results are reported. Fig. 4 shows the experimental testing results for IE3 - 2 poles induction motor; the accuracy achieved in efficiency measurement is +/- 0,30 %, by adopting high accuracy wattmeter and mechanical transducers.  We can observe that only the 5,5 kW motor is below the IE3 efficiency; however, because of the allowed 15% uncertainty in power losses measurement, the manufacturer could correctly classify it as IE3 as suggested by Fig. 5.

27. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 Fig.4 – Experimental testing results for IE3 - 2 poles induction motor, for IE classification; the accuracy achieved in efficiency measurement is +/- 0,30 %. 5. Experimental results

28. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 28 5. Experimental results Fig. 5- Possible IE3 classification of induction motors with a measured lower efficiency due to the allowed 15% uncertainty in power losses measurement.

29. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 29 5. Experimental results  This issue is more evident in Fig.6 for the 4 poles induction motors we tested ; all of them are characterized by measured efficiency lower than the IE3 curve, that we have measured with experimental uncertainty of +/-0,40%. Fig.6 – Experimental testing results for IE3 - 4 poles induction motor, for IE classification; the accuracy achieved in efficiency measurement is +/- 0,40 %.

30. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 30 5. Experimental results  Nevertheless, although all of them are below the IE3 curve, they can be classified an IE3 because the manufacturer can take advantage from allowed the15% uncertainty (Fig.7). Fig. 7 – Possible IE3 classificatin of induction motors with a measured lower efficiency due to the allowed 15% uncertainty in power losses measurement.

31. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 31 5. Experimental results  In other words, even if with a high accuracy measurement of efficiency we can demonstrate that an induction motor is below a rated IE efficiency value, the manufacturer could not be censured because the EC Regulation N. 640/2009, Annex III allows him to perform the efficiency measurement with low accuracy.

32. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 32 Outline of the presentation 1.Introduction 2.Efficiency levels 3.The IE-Code 4.Measurements and calculations 5.Experimental results 6.A proposal for a certified laboratory 7.Conclusions

33. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 33 6. A proposal for a certified laboratory  The diffusion and distribution of high performance induction motors in the new European market should be accompanied with characterization activities devoted to the experimental evaluation of actual efficiency of the motors themselves, with the main aim of guaranteeing the correct implementation of the EU standards according to the efficiency for IE levels (Annex I of EC Reg.N.640/2009).  In order to this important goal, the development of a certified laboratory is necessary, that is able to perform experimental characterization of induction motor (2, 4 and 6 poles) with rated power up to 375 kW, according to the EU standards. The laboratory should be equipped with high accuracy instrumentation and transducers, to allow the researchers to implement state-of-the-art measurement procedures.

34. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 34 6. A proposal for a certified laboratory  As a first mission, the proposed laboratory could be employed in supporting Italian and European manufacturers by implementing a wide validation activity, as required by EC Regulation N. 640/2009 concerning induction motors market surveillance according to IE2, IE3 and IE4 efficiency classes, to identify induction motors that do not comply with the required performance.  As a second mission, the proposed laboratory could successfully support the research activities in the field of high efficiency induction motors, by allowing high accuracy pre- compliance testing during the development of motor prototypes.

35. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 35 6. A proposal for a certified laboratory  The main features of the measurement certified laboratory should be the following, according to IEC 60034-2-1 and EU 640/2009: 1.Implementation of more testing benches optimized according to the sizes of the induction motors to be tested, to ensure adequate measurement accuracy in all the range 0.75 - 400 kW. 2.Power supplying based in programmable three-phase supply systems, for the generation of supply voltage up to 1000 V, with the possibility of implementing 50 and 60 Hz voltages to perform experimental tests for overseas markets. 3.Mechanical load generation by means of active brakes, to allow automatic control of the motors both in dynamic and in stazionary load conditions, and to perform tests with the rotor dragging.

36. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 36 6. A proposal for a certified laboratory 4.Recovery of the mechanical power supplied by the motors under test, by means of inverters, to reduce the energy consumption. 5.Use of different sets of high performance transducers, for mechanical and thermal measurements, tailored according to the rated values of the parameters to be acquired. 6.Use of state-of-the-art wattmeters, digital multimeters, voltage and current transducers. 7.Use of high accuracy resistance measurement devices for windings characterization. 8.Implementation of flexible and reconfigurable software to control the active brakes, to plan the tests and to acquire and to process measurement data. 9.Location of the laboratory in a suitable building, possibly in proximity of industrial agglomerations, properly served by means of transportion and couriers.

37. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 37 Outline of the presentation 1.Introduction 2.Efficiency levels 3.The IE-Code 4.Measurements and calculations 5.Experimental results 6.A proposal for a certified laboratory 7.Conclusions

38. EC Regulation N. 640/2009 and its effects on the induction motors energy efficiency test methods with …. 2014 38 7. Conclusions  The efficiency values of induction motors have heavy effects on the energy consumptions in industrial application.  In recent year, several international standards and regulations have been published, with the aim of introduce new efficiency classes and determine high accuracy procedures for the experimental measurement of motors efficiency.  Some issues concerning the experimental uncertainty and its interpretation in the efficiency measurement can be raised.  It can be difficult to determine the efficiency class of an induction motor due to the high uncertainty allowed by EC Regulation N. 640/2009, Annex III  An implementation of a certified laboratory is required to support manufacturers and researchers.