Energy Policy Act of 1992

In November of 1992, then President George Bush signed into law an energy policy act that promises to have the greatest effect on electric motor users, purchasers and manufacturers since the NEMA U to T frame rerate of 1964.

This article will attempt to clear up any myths that may have been promulgated and give as clear a definition as possible of the Energy Policy Act of 1992 (EPACT '92).

Besides electric motors, products covered by EPACT '92 include lamps, utility transformers and luminaires. For the purpose of this writing, only elements of EPACT '92 affecting electric motors will be addressed.

Energy conservation makes good sense for a number of reasons; reduced need for new power plants by curtailing overall demand, less "greenhouse gas" generated by the burning of fossil fuels, and lower operating costs by industry are a few. Electric motors have a major impact on energy conservation. 40% of all fossil fuel is used to generate electricity; the United States is the largest consumer of fossil fuels, and over half of the electricity generated is used to power electric motors of all sizes. Over the past 10 years most motor manufacturers have introduced a "higher than standard efficiency" line of motors in industrial (1-200HP) sizes, and through education of motor buyers and users, along with a variety of utility rebate programs, sales of these high efficiency motors have risen to nearly 20% of the total units sold in this range. That leaves 80% of 1-200HP units sold still on the lower "standard" efficiency platform, and its this group of product that EPACT '92 targets.

EPACT '92 stipulates that all covered product must meet the efficiency levels per NEMA MG1 1993 chart 12-10. It should be noted that the levels given on this chart are far from "cutting edge." In fact, most manufacturers premium efficiency lines exceed the levels mandated. However, since the first cost of these premium designs can easily be 30-40% more than their standard efficiency counterparts, many OEM's and user's struggle to pay the price up front for the long term savings that would be realized. EPACT '92 will effectively raise the average efficiency of platform general purpose motors by making the current "standard efficient" motors unavailable.

* General Purpose	* NEMA T-Frame	* Single Speed
* Foot Mounted	* Polyphase	* Squirrel-cage Induction
* Design A or B	* Continuous Rated	* Operating on 230/460 Volt
* Open and Enclosed designs	* Constant 60 Hertz Power	* 1-200 Horsepower
* Three-digit NEMA frame	* 2,4 or 6 pole designs	* Manuf'd after 10/24/97

EPACT '92 covers all motors sold in the United States, whether manufactured in the U.S. or imported. There is no distinction between motors being purchased for new applications or those replacing existing motors.

There are also two types of motors identified by EPACT '92 that are NOT covered, definite purpose motors and special purpose motors. Definite purpose motors are those in standard ratings and 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 key phrase in this definition is "cannot be used in most general purpose applications." A "severe duty" type motor may be designed for service conditions other than "usual," but would be covered by EPACT '92 as it certainly can be used in most general purpose applications.

The other type of motors specifically excluded from EPACT '92 are special purpose motors. These are defined as any motor, other than a general purpose motor or definite purpose motor, which has special operating characteristics or special mechanical construction, or both, designed for a particular application.

It should be noted that EPACT '92 does NOT take into consideration duty cycle when qualifying motors. A classic example would be motors for fire pump applications, normally they see very little run time and justifying the expense of a high efficiency design on a payback analysis would be impossible. However, since these motors are commonly standard three phase NEMA designs they are covered by EPACT '92. This condition covers intermittent applications such as air compressors as well.

The DOE has determined that motor testing will be per test method IEEE-112B which takes into account stray load losses. The goal is to have motor manufacturers test facilities accredited by a third party to assure that they do indeed adhere to this standard. However, since there is no deadline for establishing test procedures in the act, and specific guidelines for obtaining this certification remain undefined, the DOE will expect motor manufacturers to self certify their motor efficiencies supported by tests or computer correlation programs. Once the motor manufacturer demonstrates to the DOE's satisfaction that their products meet efficiency guidelines, a certification number will be issued indicating compliance and allowing nameplating motors to the federal regulation. This requirement may add a burden to off shore manufacturers of motors, as obtaining certification of their methods will be more difficult. Many test and nameplate to less stringent standards such as IEC 34.2, BS 269, or JEC 37.

EPACT '92 charges the DOE to establish a labeling standard for motors covered by the law that takes into account NEMA Standards MG 1-1997, requires motor efficiency on the permanent motor nameplate, motor efficiency prominently displayed in all catalogs and marketing tools, and any other markings deemed appropriate. The "other markings" referred to imply a recognizable logo that identifies the motor as meeting the requirements of EPACT '92, thereby making it easier for an informed purchaser to make an energy conscious buying decision. Currently, an "ee" mark similar to a UL or CSA insignia has been proposed. The DOE has 12 months to finalize labeling requirements after establishment of test procedures. EPACT '92 establishment of test procedures are expected to be issued with the final rule. DOE has indicated that manufactures will have 24 months after issuance to comply with the rule.

The standards will become effective for all covered motors on October 24, 1997. A two year extension (10/24/1999) is allowed for motors requiring listing or certification through a nationally recognized safety testing laboratory, such as UL. This would include all explosion proof motors listed for hazardous locations. Once effective, the statuary standards will be applicable for at least five years.

EPACT '92 has teeth. Penalty for a motor manufacturer selling product after October 24, 1997, that does not meet the energy guidelines is $100 per unit. DOE reserves the right to pull motors from inventory or off the manufacturers line for spot testing by an independent lab to verify adherence. Test records or correlation files can also be demanded to verify nameplate accuracy. If evidence is produced that a manufacturer is violating the standard the result could be a civil trial and subsequent lawsuit. Expect some degree of self policing within the industry, with motor manufacturers assuring that all are on a common field of play.

EPACT '92 will have virtually no effect on motor buyers already standardizing on premium efficient designs available today. It will have a major effect on the 80% of the market still buying on general purpose and modified standard efficient platforms. Because of the need for additional active material, special lamination steels and special or additional processes the initial purchase price of premium efficient motors is significantly higher than standard efficient designs, perhaps as much as 40% on smaller frames where active material is a greater percentage of total motor cost. There may be some performance concerns in a small number of motor applications as well. Energy efficient motors tend to have less "slip" (theoretical RPM / actual full load RPM) resulting in operation at slightly higher speeds than standard efficient designs. On variable torque applications such as centrifugal fans or pumps the load increases with the cube of the speed change, meaning a little higher RPM can result in an appreciable load increase on the motor that could create an overload condition, or possible damage to other system components. Another phenomena of high efficient motors is that they tend to draw higher amps at start, or "locked rotor." This could necessitate a re-sizing of starters, fuses or other system components in some applications. High efficiency motors tend to weigh more than standard designs so base rigidity could be an issue along with changes in system reed frequencies. Original equipment manufacturers must also go through the effort of changing part numbers and prints to reflect the new designs. Those with system agency recognition may need to have their products re-certified.

The effects will certainly not all be negative. Slightly higher shaft speeds could result in work being completed quicker. Because of fewer losses and greater thermal mass, high efficiency motors often operate cooler, resulting in longer bearing and insulation life. Cooler operation also means these units may lend themselves better to applications in constricted areas where ambient temperatures could increase to undesirable levels. Totally enclosed high efficient motors often have smaller less noisy cooling fans making them more user friendly. And of course, high efficient motors will definitely reduce energy costs.

For reasons stated in the beginning of this article, U.S. Motors supports the increased use of energy efficient motors. Over the past 15 years U.S. Motors has developed a broad offering of proven energy efficient products and today is a leading supplier of high efficiency motors to the world. It is our intent to fully comply with the intent of EPACT '92 and will continue to work closely with the DOE and NEMA to assure it's fair and equitable implementation.

The greatest concern we had with the act is the additional cost involved with manufacturing energy efficient motors and passing that burden on to our good customers. For that reason, several years ago we began an extensive efficiency general redesign program on all our standard purpose motors. Our goal was to create a whole new platform of energy efficient motors utilizing Emerson Electric's world leading technology. Besides meeting standards mandated by EPACT '92, these efficiency motors would also comply with the standards of Canada and Mexico, and evolving standards in the Pacific rim and Asia. Along with 60 hertz efficiency they would also offer extreme flexibility, able to operate on 50 hertz power, connectable for both across-the-line and wye-delta starting. The CE mark will be displayed on the nameplate allowing acceptance in the countries of the European Community.

U.S. Motors is proud to introduce the WORLD MOTOR, available in the full line of ratings covered by EPACT '92 in both open dripproof and TEFC enclosures. Please contact your local U.S. Motors Distributor or Sales Engineer for all the details of this exciting new generation of motors.