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History
Since 2009, the European Union (EU) Commission has been working towards reducing energy consumption through legislation governing eco-design requirements for all energy-related products. At that time, it was estimated that there were about 85 million large electrical motors in operation throughout the EU, consuming around 65-70% of all energy used in industry.
To address this, the Commission enacted Regulation (EC) No 640/2009, which mandated that single-speed, three-phase, 50 Hz or 50/60 Hz squirrel cage induction motors for continuous duty, with 2 to 8 poles and power ratings between 0.75 kW and 375 kW, must meet specific efficiency levels.
According to that regulation:
- Motors with a rated output of 7.5 to 375 kW had to meet the IE2 efficiency level by 16 June 2011.
- Motors with a rated output of 0.75 to 375 kW had to meet the IE2 efficiency level by 1 January 2015.
- From 1 January 2017, motors with a rated output of 0.75 to 375 kW had to meet the IE3 efficiency level, or the IE2 efficiency level if equipped with a variable speed drive.
Commission Regulation (EU) 2019/1781
Commission Regulation (EC) No 640/2009 remained in effect until 30 June 2021 and was subsequently repealed and replaced by Commission Regulation (EU) 2019/1781, which introduced updated requirements and came into force on 1 July 2021. This marked the implementation of the next phase of the directive, broadening the scope of the regulations to cover a wider range of electric motors. The prescribed changes are estimated to deliver roughly 10 TWh of energy savings by 2030, significantly reducing greenhouse gas emissions.
The new regulation expands the scope and introduces stricter efficiency requirements for motors and variable speed drives (VSDs). For the first time, it includes 60 Hz motors, brake motors with external brakes, and motors designed for use in hazardous environments. Additionally, VSDs with a rated voltage above 100V and up to and including 1000V AC are now included within the scope.
Here's a brief outline of the new energy efficiency levels and requirements:
Energy Efficiency Requirements for Electric Motors:
IE2 Efficiency Level:
- Motors with a rated output between 0.12 kW and 0.75 kW.
IE3 Efficiency Level:
- Motors with a rated output from 0.75 kW to 1000 kW (inclusive).
- Both 2-, 4-, 6-, and 8-pole motors are included.
IE4 Efficiency Level:
- Motors with a rated output from 75 kW to 200 kW.
IE5 Efficiency Level:
- This regulation encourages the development and market adoption of motors with even higher efficiencies (beyond IE4), although IE5 is not yet mandated.
Energy Efficiency Requirements for Variable Speed Drives:
IE2 Efficiency Level:
- Variable speed drives with a rated output between 0.12 kW and 1000 kW.
Key Dates for Implementation:
As of 1 July 2021:
- IE3 mandatory for motors with rated outputs between 0.75 kW and 1000 kW.
- IE2 mandatory for motors with rated outputs between 0.12 kW and 0.75 kW.
- IE2 mandatory for variable speed drives with rated outputs between 0.12 kW and 1000 kW.
A comprehensive table detailing all aspects of the New Regulation (EU) 2019/1781 - Step 1 for Motors, from 1 July 2021, is provided below:
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Characteristics
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Motors included in the regulation
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Motors excluded from the regulation
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Type of motor
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Squirrel cage induction motor
Open and closed motors.
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Wound rotors, DC, permanent magnet.
Motors specifically designed to operate wholly immersed in water.
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Speed
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Single speed motors, for fixed speed or VSD application.
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Motors with multiple windings or with a switchable winding providing a different number of poles and speeds.
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Mounting
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Motors completely integrated into a product of which the energy performance can be tested independently from the product.
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Motors completely integrated into a product of which the energy performance cannot be tested independently from the product.
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Frequency
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50 Hz, 60 Hz and 50/60 Hz
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Others
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Poles
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2,4,6, 8
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10 poles or higher
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Rated Voltage
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50 up to 1,000 V
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Above 1,000 V
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Rated Output
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3 phase motors 0.75 - 1,000 kW must meet IE3
3 phase motors 0.12 kW - 0.75 kW (not incl.) must meet IE2
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3 phase motors below 0.12 kW and above 1,000 kW
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Duty Cycle
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Continuous duty operation (S1),S3>= 80%, or S6>= 80%
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Intermittent duty operations such as S2, S4, S5 etc.
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Altitude
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Up to 4000 m.a.s.l
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Above 4000 m.a.s.l
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Ambient air temperature
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All motors -30°C to 60°C
Water cooled motors 0°C to 32°C
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All motors below -30°C or above 60°C
Water cooled motors below 0°C or above 32°C
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Cooling
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Air: TEFC, TEAO, TEBC
Water: Coolant temperature at the inlet is between 0°C and 32°C
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Air: TENV - Totally Enclosed Non-Ventilated Water:
Coolant temperature at the inlet is less than 0°C or higher than 32°C
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Maximum operating temp
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Up to 400˚C
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Above 400˚C
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Brake
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Brake motors with external brake
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Motors with an integrated brake where the brake is an integral part of the inner motor construction and can neither be removed nor supplied by a separate power source during the testing of the motor efficiency.
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Area classification
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Explosion-protected motors 'Ex ec', 'Ex tb', 'Ex tc', 'Ex db', 'Ex dc' or 'Ex db eb'
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Explosion protected motors for mining as defined in Annex 1, Point 1 of Directive 2014/34/EU
Increased safety motors of the Ex eb type
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Variable Speed Drive Motors
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When able to be equipped with a VSD must meet the same rules for motors without VSD.
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Motors with integrated variable speed drive (compact drives) of which energy performance cannot be tested independently from the variable speed drive
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Others
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Motors specifically qualified for the safety of nuclear installations, as defined in article 3 of Directive 2009/71/EURATOM
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Motors in cordless or battery operated equipment
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Motors in hand-held equipment whose weight is supported by hand during operation
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Motors in hand-guided mobile equipment moved while in operation
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Motors with mechanical commutators
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Motors specifically designed for electric vehicles
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As of 1 July 2023:
- IE4 mandatory for motors with rated outputs between 75 kW and 200 kW.
- IE3 mandatory for explosion-proof motors and brake motors with rated outputs between 0.75 kW and 1000 kW.
All aspects of the New Regulation (EU) 2019/1781 - Step 2 for Motors, effective from 1 July 2023, are provided in the table below:
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Characteristics
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Motors included in the regulation
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Motors excluded from the regulation
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Type of motor
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Squirrel cage induction motor
Open and closed motors.
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Wound rotors, DC, permanent magnet. Motors specifically designed to operate wholly immersed in water.
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Speed
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Single speed motors, for fixed speed or VSD application.
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Motors with multiple windings or with a switchable winding providing a different number of poles and speeds.
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Mounting
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Motors completely integrated into a product of which the energy performance can be tested independently from the product.
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Motors completely integrated into a product of which the energy performance cannot be tested independently from the product.
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Frequency
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50 Hz, 60 Hz and 50/60 Hz
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Others
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Poles
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2,4,6, 8 poles
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10 poles or higher
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Rated Voltage
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50 up to 1,000 V
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Above 1,000 V
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Rated Output
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3 phase motors 0.12 up to 0.75 kW (not included) must meet IE2.
3 phase motors 0.75 kW -1,000 kW must meet IE3 3 phase motors: 2, 4 and 6 pole, 75 kW up to 200 kW must meet IE4.
Single-phase: 0.12kW and above must meet IE2
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3 phase motors below 0.12 kW and above 1,000 kW.
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Duty Cycle
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Continuous duty operation (S1),S3>= 80%, or S6>= 80%
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Intermittent duty operations such as S2, S4, S5 etc.
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Altitude
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Up to 4000 m.a.s.l
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Above 4000 m.a.s.l
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Ambient air temperature
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All motors: -30°C to 60°C
Water cooled motors 0°C to 32°C
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All motors: below -30°C or above 60°C
Water cooled motors below 0°C or above 32°C
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Cooling
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Air: TEFC, TEAO, TEBC
Water: Coolant temperature at the inlet is between 0°C and 32°C
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Air: TENV - Totally Enclosed Non-Ventilated
Water: Coolant temperature at the inlet is less than 0° C or higher than 32°C
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Maximum operating temp
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Up to 400˚C
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Above 400˚C
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Brake
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Brake motors with external brake
0.12kW up to 0.75 kW (not incl.) must meet IE2
0.75 kW up to 1,000 Kw must meet IE3
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Motors with an integrated brake where the brake is an integral part of the inner motor construction and can neither be removed nor supplied by a separate power source during the testing of the motor efficiency.
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Area classification
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Explosion-protected motors 'Ex ec', 'Ex tb', 'Ex tc', 'Ex db', 'Ex dc' or 'Ex db eb'
0.12kW up to 0.75 kW (not incl.) must meet IE2
0.75 kW up to 1,000 Kw must meet IE3 Ex be
Equal or above 0.12 kW and equal or below 1,000 kW must meet IE2
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Explosion protected motors for mining as defined in Annex 1, Point 1 of Directive 2014/34/EU
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Variable Speed Drive Motors
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When able to be equipped with a VSD must meet the same rules for motors without VSD.
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Motors with integrated variable speed drive (compact drives) of which energy performance cannot be tested independently from the variable speed drive.
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Others
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Motors specifically qualified for the safety of nuclear installations, as defined in article 3 of Directive 2009/71/EURATOM.
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Motors in cordless or battery-operated equipment.
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Motors in hand-held equipment whose weight is supported by hand during operation.
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Motors in hand-guided mobile equipment moved while in operation.
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Motors with mechanical commutators.
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Motors specifically designed for electric vehicles.
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3-phase general motors
Ex tb, Ex tc, Ex ec, Ex dc, Ex db
Ex db eb and brake motors
Ex eb motors and 1-phase motors
Specific Exclusions:
Excluded from the regulation are certain motor types and applications such as:
- Motors specifically designed for hazardous environments.
- Motors integrated into products where their energy performance cannot be tested independently.
- Motors designed for variable speed operations that do not comply with fixed speed motor test conditions.
Variable Speed Drives (VSD)
From July 1st, 2021, Variable Speed Drives (VSDs) have also fallen within the remit of the EU 2019/1781 regulation. Initially, the regulation covers 3-phase standard VSDs with power ratings from 0.12 kW to 1000 kW and a rated voltage above 100V up to and including 1000V. The power losses of VSDs rated for operating with motors in this power range shall not exceed the maximum power losses corresponding to the IE2 efficiency level.
Major exemptions are:
- VSDs integrated into a product whose energy performance cannot be tested independently from the product.
- Regenerative drives.
- Multiple AC-output drives.
The regulation is valid for:
- New motors/VSDs placed on the market for the first time.
- Replacement motors, as substitutes for identical motors integrated into products placed on the market until 1st July 2022 and specifically marketed for this purpose, do not have to meet the requirements of the new regulation and may be supplied according to (EC) 640/2009 until 1st July 2029.
Objective:
The regulation aims to improve the energy efficiency of electric motors and drives, thereby reducing energy consumption and greenhouse gas emissions in line with the EU's broader climate and energy goals.
These requirements are intended to drive innovation in motor and drive technology, leading to more energy-efficient products on the market and ultimately contributing to the EU's sustainability objectives.
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