EPACT ENERGY POLICY OF 1992: THE SCOPE OF ELECTRIC MOTORS SUBJECT TO EFFICIENCY STANDARDS ON OCTOBER 24, 1997
The Energy Policy Act of 1992 (EPAct) covering efficiency levels of general purpose industrial motors is effective October 24, 1997. The basic intent of the law is to reduce the rate of energy consumption in the U.S. by requiring the use of energy efficient products. In an attempt to accomplish this goal, EPAct mandates that most industrial AC motors imported or produced for sale in the United States must meet energy-efficient requirements as defined by Table 12-10 from NEMA Standard MG 1. As expected, a sweeping government mandate such as EPAct has raised many questions. And even after all this time, many remain unanswered. The answer to the most basic question, What products are actually covered by EPAct?, is the subject of this NEMA brochure. As you will see, some motors are clearly covered; some are clearly not, and some will receive a two-year delay in enforcement. Which motors are covered? is the primary concern of both motor manufacturers and consumers since product redesigns are required to raise many existing standard motor types to the new efficiency standards. The information presented here is based on the U.S. Department of Energy s interpretations of the law and DOE s position on the scope of products covered and non-covered (exempt) by the legislation. Motor users and OEMs can refer to the enclosed information to determine whether the motors they purchase will be covered by EPAct and therefore must meet the standard energy-efficiency levels. Which Efficiency Standards? The efficiency levels which general purpose industrial motors covered by EPAct must meet by October 24,1997, are the same as those listed in NEMA MG 1, Table 12-10 for 3600, 1800 and 1200 RPM (2- pole; 4-pole, 6-pole) motors operating on 230/460 V, 60 Hz constant line power. In other words, a motor currently described as energy-efficient in accordance
with NEMA guidelines already meets the EPAct requirements. All efficiency measurements are to be performed in accordance with IEEE Standard 112, Test Method B. EPAct required full-load efficiencies are listed in the following table. Table 12-10: NOMINAL FULL-LOAD EFFICIENCIES OPEN MOTORS ENCLOSED MOTORS Hp 2 POLE 4 POLE 6 POLE 2 POLE 4 POLE 6 POLE 1.0... 82.5 80.0 75.5 82.5 80.0 1.5 82.5 84.0 84.0 82.5 84.0 85.5 2.0 84.0 84.0 85.5 84.0 84.0 86.5 3.0 84.0 86.5 86.5 85.5 87.5 87.5 5.0 85.5 87.5 87.5 87.5 87.5 87.5 7.5 87.5 88.5 88.5 88.5 89.5 89.5 10.0 88.5 89.5 90.2 89.5 89.5 89.5 15.0 89.5 91.0 90.2 90.2 91.0 90.2 20.0 90.2 91.0 91.0 90.2 91.0 90.2 25.0 91.0 91.7 91.7 91.0 92.4 91.7 30.0 91.0 92.4 92.4 91.0 92.4 91.7 40.0 91.7 93.0 93.0 91.7 93.0 93.0 50.0 92.4 93.0 93.0 92.4 93.0 93.0 60.0 93.0 93.6 93.6 93.0 93.6 93.6 75.0 93.0 94.1 93.6 93.0 94.1 93.6 100.0 93.0 94.1 94.1 93.6 94.5 94.1 125.0 93.6 94.5 94.1 94.5 94.5 94.1 150.0 93.6 95.0 94.5 94.5 95.0 95.0 200.0 94.5 95.0 94.5 95.0 95.0 95.0 What s Covered? EPAct begins by declaring that all general purpose motors are covered by the new efficiency requirements. EPAct defines general purpose as those motors meeting the following conditions: Single-speed, polyphase T frame 1 through 200 HP 3600, 1800 or 1200 RPM Foot-mounted Squirrel-cage induction motors, NEMA Design A and B Continuous rated Operating on 230/460 volts, constant 60 Hertz line power as defined in NEMA Standard MG 1
NEMA s Product Ma Covered Not Covered Motor/Modification 10/24/97 Covered 10/24/99 A: ELECTRICAL MODIFICATIONS Altitude Ambient Multispeed Special leads Special Insulation Encapsulation High service factor Space heaters Wye delta start Part winding start Temperature rise Thermally protected Thermostat/thermistor Special voltages Intermediate horsepowers Frequency Fungus/trop. insulation B: MECHANICAL MODIFICATIONS Special balance Bearing temp. detector Special base/feet Special conduit box Auxiliary conduit box Special paint/coating Drains Drip cover Ground. lug/hole Screens on ODP enclosure Mounting F1,F2; W1-4; C1,2 C: BEARINGS Bearing caps Roller bearings Shielded bearings Sealed beardings Thrust bearings Clamped bearings Sleeve bearings D: SPECIAL ENDSHIELDS C face D flange Customer defined E: SEALS Contact seals Non-contact seal F: SHAFTS Standard shafts/nema MG 1 Non-standard material G: FANS Special material Quiet design H: OTHER MOTORS Washdown Close-coupled pump Integral gear motor Vertical-normal Thrust Saw arbor TENV TEAO Fire pump Non-continuous Brake
trix EPLANATION General purpose up to a frame series change larger General purpose up to a frame series change larger EPCA applies to single speed only Due to special construction General purpose up to a frame series change larger General purpose up to a frame series change larger Require retesting and third-party agency approval EPCA applies to motors operating on 230/460 voltages at 60 Hertz. Round HP according to 10 CFR 431.42 for efficiency EPCA applies to motors operating on 230/460 voltages at 60 Hertz. Does not meet definition of T-frame Foot-mounting, rigid base, and resilient base Test with a standard bearing Test with a standard bearing Special mechanical construction Special mechanical construction As defined in NEMA MG 1 As defined in NEMA MG 1 Special design for a particular application Includes lip seals and taconite seals-test with seals removed Includes labyrinth and slinger seals-test with seals installed Includes single and double, cylindrical, tapered, and short shafts. Test with seals removed. JM and JP frame assignments. Special mechanical design - not a T-frame. Motor and gearbox inseparable and operate as one system. EPCA covers foot-mounting Special electrical/mechanical design Totally-enclosed non-ventilated not equipped for cooling (IP54, IC410) Totally-enclosed air-over requires airflow from external source (IP54, IC417) When safety certification is not required. See EPCA section 342 (b) (2) EPAct covers continuous ratings Integral brake design factory built within the motor
NEMA s Product Matrix Using these general guidelines in conjunction with definitions from EPAct, NEMA developed a matrix to illustrate whether many common features or motor variations fall within the motors covered by EPAct. This matrix is not intended to be all-inclusive. Rather, it is a set of examples demonstrating how the definitions and guidelines would be applied to various motor types. By extension of these examples, a motor currently in production, or to be designed in the future, can be classified. This summary categorizes the features and options into three categories: 1) general purpose covered as of October 24, 1997 2) definite purpose, special purpose, or falling outside the scope of EPAct. 3) general purpose covered as of October 24, 1999 DOE has established a temporary exemption for motors that go into UL-listed products. This would be handled on a case-by-case basis. NEMA Design A or B motors that meet all other criteria under the definitions in EPAct for covered products and are also suitable for inverter use as an additional feature still are covered products under EPAct. In other words, being suitable for use on an inverter, by itself, does not exempt a motor from EPAct. Exclusions from EPAct Requirements This definition immediately excludes a specific set of motor types from the EPAct requirements. Those types excluded are listed below. This is not an all-inclusive list. (1) footless designs (2) horsepower sizes below 1 and above 200 (3) 900 rpm and slower speeds (4) two-speed versions (5) 50 Hertz (6) 200/400, and 575 volt (7) Design C and D (8) U Frame (9) inverter duty motors (Note: Being suitable for use on an inverter, by itself, does not exempt a motor from EPAct.)
(10) single phase motors (11) frame sizes 56 and smaller While lawmakers attempted to follow the general, special, and definite purpose definitions from NEMA s MG 1, there were some distinctive changes in the definition for definite-purpose motors that have resulted in considerable confusion within the motor community. The law defines definite purpose motors as follows: any motor designed in standard ratings with standard operating characteristics or standard mechanical construction for use under service conditions other than usual or for use on a particular type of application and which cannot be used in most general purpose applications. The last phrase,...and which cannot be used in most general-purpose applications, is the key to understanding whether a particular motor must meet the EPAct energy standards. DOE s Enforcement Policy These guidelines clarify the above definition as to whether a motor is classified as a covered product or an exempt product. Motors with features or characteristics that do not meet the definition of a general-purpose motor as defined in EPAct are non-covered products and are exempt from EPAct. Motors designed for use on a particular type of application that are in a frame size that is one or more frame series larger than the frame size assigned to that rating by Tables 2 and 3 from NEMA Standard MG 13, should not be considered usable in most general purpose applications and would therefore be exempt from EPAct. Motors built in frame series or sizes smaller than that called out by MG 13 should still be considered as usable in most general-purpose applications and covered by EPAct. Examples: Consider a 3 hp 1800 RPM T frame motor. The assigned frame size for this motor is 182T. If a motor manufacturer produced that same rating in a 184T frame, it is considered to be within the same frame series (180 T frame series includes the 182T and 184T frames) and is covered by EPAct.
What if a 3 hp 1800 rpm motor was available in a 145T frame? This motor would also be covered under EPAct since it is in a smaller frame series (the 140 series). The same 3 hp 1800 rpm rating in a 215T frame is not covered by EPAct because it is in a large frame series (the 210 series). Contact seals can be removed from the motor when performance is determined for compliance and enforcement. (Contact seal drag reduces motor efficiency.) The nameplated efficiency for these motors would reflect their performance without these devices installed. Electrical modifications are categorized according to their conformity with NEMA (or metric equivalent) performance standards. For example, modified torque characteristics that still meet the NEMA Design A or B performance requirements are considered covered product. If the characteristics meet NEMA Design C or D requirements, the motor is exempt. In order for a motor to be classified as Design C or D, the motor must meet all performance standards for the stated Design type. NEMA will continue to work with DOE to further clarify the implementation of EPAct. As additional information is obtained, NEMA will distribute additional information via brochures and through NEMA s website. DOE will permit a temporary extension of time for compliance for motors that go into products that require redesign to accomodate the more efficient motor or that require listing or certification by a third party agency such as UL or CSA. This would be handled on a case-by-case basis based on submittal of a joint request for the extension by the OEM and the motor manufacturer. This brochure is based on information received from the U.S. Department of Energy in September 1997. DOE may choose to revise their existing guidance. To obtain a copy of DOE's motor enforcement policy guidance either contact NEMA or DOE at their website: www.eren.doe.gov NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION 1300 NORTH 17TH STREET, SUITE 1847 ROSSLYN, VIRGINIA 22209-3801 (703) 841-3200 FA: (703) 841-5900 WWW.NEMA.ORG 9/97