IE3-IE4 premium-efficiency motors: choosing

the right motor control and protection components

White Paper

schneider-electric.com
Table of Contents

Introduction........................................................................................................................................................................................................... 5

1. The drive for energy efficiency.............................................................................................................................................. 6

1.1. Industrial motors: a key contributor to consumption­­­–and potential savings..................................................... 6

1.2. New motor-efficiency standards........................................................................................................................................................ 7

1.2.1. The European Union............................................................................................................................................................................... 7

1.2.1.1. What the new EU regulations and standards say........................................................................................................ 7

1.2.1.2. Exceptions to the European MEPS.......................................................................................................................................... 8

1.2.2. Regulations and standards in other parts of the world................................................................................................ 9

2. What you need to know about asynchronous motors before you choose.................. 10
2.1. Direct on line (DOL) starting.............................................................................................................................................................. 10

2.1.1. Inrush current............................................................................................................................................................................................ 10

2.1.2. Protection for DOL starters............................................................................................................................................................. 11

2.2. Premium-efficiency motors.................................................................................................................................................................. 12

2.2.1. Design characteristics........................................................................................................................................................................ 12

2.2.2. Premium-efficiency motor current load................................................................................................................................. 13

2.2.3. The influence of efficiency on locked rotor current...................................................................................................... 14

2.2.4. The influence of the electrical installation on starting current and inrush peak current.................. 15

2.3. Selecting the right protective devices......................................................................................................................................... 16

2.3.1. Circuit breaker and thermal relay.............................................................................................................................................. 16

2.3.2. Contactor...................................................................................................................................................................................................... 17

2.3.3. Coordinating the circuit breaker and contactor.............................................................................................................. 17

3. Getting started with TeSys by Schneider Electric..................................................................................... 18

References......................................................................................................................................................................................................... 19

schneider-electric.com/TeSys July 2017 | 2

Executive summary
Amid mushrooming global demand for energy and increasing concern
for the environment, countries around the world are implementing tighter
environmental restrictions. Industrial motors, a major global consumer
of electricity, are one of the prime targets of the new regulations
and standards.

The transition to IE3 premium efficiency motors and IE4 super premium
efficiency motors is underway, raising challenges for businesses.
However, these challenges also bring opportunities for businesses
to reduce energy costs and increase efficiency while lightening their
impact on the environment.

To make the right motor starter choices and ensure maximum energy
efficiency, it is important to be aware of how IE3 premium efficiency
motors behave during starting and the impact this behavior can have on
protective devices. Schneider Electric TeSys motor starter products (motor
circuit breakers, overload thermal relays, and contactors) have undergone
extensive laboratory testing with different motor brands to confirm their
compatibility with IE3 and IE4 motors

The guidelines in this white paper are designed to help you make the right
choices according to your electrical installation and motor.

schneider-electric.com/TeSys July 2017 | 3

Glossary
IE3: Premium-efficiency class for single-speed motors according
to IEC 60034-30.

IE4: Super Premium-efficiency class for single-speed motors according

to IEC 60034-30 version 2014.

DOL (direct on line) motor starter: The simplest type of motor starter,
also includes protection devices, and in some cases, monitoring.

Inrush peak: A short, high-current transient occurring during the first

milliseconds when the motor is started.

MEPS (Minimum Energy Performance Standard): Local regulation

specifying the minimum required energy performance for enery-using
products. In Europe the EU MEPS for direct on line motors is IE3.

LRA (Locked Rotor Amps), also called LRC (Locked Rotor Current):
The amount of electrical current drawn at the moment the motor is started,
but not yet turning.

OEM: Original Equipment Manufacturer.

RMS (Root Mean Square): The RMS value of an AC supply is the steady
DC equivalent, which would convert electrical energy to thermal energy
at the same rate in a given resistance.

VSD: Variable speed drive.

schneider-electric.com/TeSys July 2017 | 4

Introduction
Worldwide demand for energy is expected to double by 2050. Growing
concern for the environment is driving the emergence of more stringent
energy-efficiency regulations around the globe. And the industrial sector
is on the front lines. Electric motors account for 70% to 80% of electricity
consumption in the industrial sector, making them a prime target for
energy-saving measures.

Legislators are addressing energy efficiency in the industrial sector with

new regulations. The EU Directive on Energy-related Products (ErP) came
into force in 2009. And, since January 2015, the Directive has required
most direct on line motors to be of the IE3 premium-efficiency class
or higher.

Recent market research by global information company IHS revealed

the continued gradual market penetration of IE3 motors. Because motor
regulations are not strictly enforced, the transition is expected to remain
gradual. Despite demand from customers for IE3 motors and, more
generally, energy-efficient solutions, some OEMs continue to offer IE1.
As customers begin to include IE3 or even IE4 motors in their
requirements, the market will inevitably shift toward these motors.

The arrival of these new motors at industrial sites across Europe has
created some new challenges. Most notably, these motors’ electrical
behavior is different than their less-efficient counterparts, with typically
higher inrush peaks and locked rotor currents. Standard motor starters
and related equipment could therefore be inadequate in some cases.

This paper begins with a review of the new standards for high-efficiency
motors and the work currently being done by the international standards
technical committees to update motor and motor starter standards.
It then continues with a discussion of how the new IE3/IE4-class motors
affect direct on line starting. Finally, it provides guidelines for selecting the
most energy-efficient and robust motor starters for IE3/IE4 motors.

schneider-electric.com/TeSys July 2017 | 5

1. The drive for energy efficiency

1.1. Industrial motors: a key contributor to consumption–

and potential savings
Worldwide demand for energy is expected to double by 2050.
At the same time, governments are under pressure to halve their countries’
CO2 emissions to head off climate change before it is too late.1

If we are to find a solution, we must look beyond measures like turning off

42%
the lights when we leave a room and target the biggest energy consumers.
For example, according to the International Energy Agency, electric motors 2/3
account for 40% of total global electricity consumption, coming in ahead
Factories account for Two thirds of a typical
of lighting, a far better-known culprit, which weighs in at just 19%.
42% of total worldwide plant’s electricity
Industry is also a major global energy consumer. And the electric motors electricity consumption attributed to motors
used in many industrial plants typically consume 65% to 80% of total plant
electricity. On a global scale, industrial motors represent 28% of total
worldwide electricity consumption. This is no surprise when you consider
that an estimated 300 million industrial motors worldwide are running
at full speed for extended periods of time.

More efficient industrial motors can have a huge impact on energy

consumption and generate substantial cost savings for plants. The German
Federal Environmental Agency has estimated that increasing motor
efficiency could save 135 billion kWh and 63 million tons of carbon dioxide
(CO2) by 2020 in the EU alone. In the United States, the NEMA (National 28%
Electrical Manufacturers Association) Premium® energy efficiency motor
Industrial motors use
program is also expected to save 5,800 Gigawatts of electricity and
28% of all electricity
80 million tons of carbon dioxide over the next ten years.
worldwide

Savings potential

35%

30%

25%

20%

15% 17%
10%
Residential and non-
5%
industrial commercial
0% Motor rated power motors account for
0.75 kW 4 kW 10 kW 30 kW 70 kW 130 kW
< 0.75 kW to to to to to to < 500 kW 17% of electricity
< 4 kW < 10 kW < 30 kW < 70 kW < 130 kW < 500 kW consumption

Figure 1. Energy-efficient motors have the potential to generate huge savings in the
industrial sector.

45%
Motors in all sectors
(residential, commercial,
industrial) use 45% of all
IEA International Energy Agency
1
electricity

schneider-electric.com/TeSys July 2017 | 6

1.2. New motor-efficiency standards
1.2.1. The European Union

The European Union’s Ecodesign Directive (Directive 2009/125/EC)

provides EU Member States with a framework for their energy-efficiency
legislation. Most notably, the Directive requires manufacturers to design
energy efficient products.

The incandescent light bulb is perhaps the best-known example:

the EU outlawed the energy-hungry bulbs in 2009, spurring the emergence
of eco-halogen bubble, LED, and other high-efficiency lamps.
The Directive also covers other types of products, from home appliances
and electronics to building materials like windows and insulation
and–crucially–industrial motors.

1.2.1.1. What the new EU regulations and standards say

Implementation in the member states will take place through instruments
like laws, regulations, and standards, such as regulation EC 640/2009
on ecodesign requirements for electric motors, which came into force
in January 2015, and the associated parts of IEC 60034 harmonizing
standards for motor ecodesign.

IEC60034-30 sets forth new energy-efficiency classes for single-speed,

three-phase, cage-induction motors with two, four, or six poles. According
to this standard, motors from 0.75 kW up to 375 kW make up the vast
majority of the installed motor base2. Therefore, the standard defines IE3 EFF1
efficiency for outputs within this range. IE2
IE1
EFF2

100
The four energy-efficiency classes in the standard are:
• IE1 (standard efficiency),
90
Efficiency

• IE2 (high efficiency), and, of particular interest in this paper,

• IE3 (premium-efficiency). 80

• IE4 (super-premium-efficiency). Classification

acc. to CEMEP
70
IE3-class, or “premium-efficiency,” motors are more energy-efficient
1,5 3,5 18,5 45 110 250 375
than their EFF1- and EEF 2-rated equivalents. (EFF 1, EFF 2, and EFF 3 Power
were the three classes issued in 1998 by the European Committee of Figure 2. Comparison of IE1, IE2, and IE3 motors to
Manufacturers of Electrical Machines and Power systems, or CEMEP, their EFF1 and EFF2 predecessors.
and compliance with the classification was voluntary. The IEC classification
replaced this older system).
The new classes will become mandatory according to the following
timeline:
• All motors must be IE2 by June 16, 2011.
• All motors with output between 7.5 kW and 375 kW must be IE3
by January 1, 2015; or IE2 if a variable speed drive is used.
• All motors with output between 0.75 kW and 375 kW must be IE3
by January 1, 2017.

While IE2 motors will still be permitted when used with a variable speed
drive, this is not necessarily the most energy-efficient choice. Variable
speed drives create significant additional power losses and should be
used only when they improve the overall energy efficiency, considering the
characteristics of the whole application. Read on to learn what factors you
should include in your decision to make the right motor equipment choices
for your needs (http://www.capiel.eu/data/6685-Capiel-Tryptique-EN2-
Version-Web.pdf).
2
International Electrotechnical Commission, 2014

schneider-electric.com/TeSys July 2017 | 7

1.2.1.2. Exceptions to the European MEPS
When making your choice, it is important to know which types of motors
are exempt from the new efficiency regulations. Transport of goods and
persons are excluded from the ErP Directives. Therefore specific motors
used for lifting, hoisting, etc. are not in the scope of regulation
EC 640/2009.

The IEC60034 standard includes only motors rated either duty-type S1

or S3, with a rated cyclic duration factor (CDF) of 80% or higher.

Continuous duty Intermittent periodic duty with CDF >80%

The motor works at a constant Ratio between the period of loading and the
load for enough time to reach duration of the duty cycle.
temperature equilibrium.
Cdf = total on-times (t1+t2+t3…) ∙ 100[%]
(cycle duration (T)]

Table 1. Determining whether a motor is continuous or intermittent duty.

Motors that do not meet these specifications do not need to be IE3

(premium-efficiency). In fact, premium-efficiency motors are not
recommended for intermittent or periodic duty. This is due to the fact that
any efficiency gains are very much decreased when the motor is stopped
frequently. Motor utilization categories AC-4 are not appropriate with
IE3 motors, which would not be efficient (and which are not required
by the standard) for this type of use.

IE3 motor required/recommended IE3 motor not required/

recommended

• have a rated voltage UN up to 1 000 V • Motors immersed in liquid

NOTE: the standard also applies to motors rated • Brake motors or motors
for two or more voltages and/or frequencies. integrated into a machine
• have a rated output PN between 0,75 kW (e.g. pump, fan, compressor)
and 375 kW and that cannot be tested
• have either 2, 4 or 6 poles separately from the machine
• are rated on the bases of either duty type S1 • Motors made solely for
(continuous duty) or S3 (intermittent periodic converter operation
duty) with a rated cyclic duration factor of 80 % • Motors used to transport
or higher people or goods (lifts,
• are capable of operating direct on-line elevators, hoists, conveyors)
• are rated for operating conditions in • Intermittent-duty motors with
accordance with IEC 60034-1, Clause 6 rated CDF of under 80%

Table 2. In some instances, IE3 motors are not required or even recommended.

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1.2.2. Regulations and standards in other parts of the world

United States

In the United States, NEMA, the National Electrical Manufacturers

Association, has rolled out an initiative similar to what is being seen
in Europe with the NEMA Premium® Motors program, a label equivalent
to IE3 premium-efficiency. NEMA Premium® motors account for an
estimated 20% of market share in the US (2015). High prices and low
ROI are slowing the widespread adoption of these motors. Their design
disruption is lower than in Europe due to their de facto savings of 20%
thanks to the frequency of 60 Hz in addition to their longer frame
(NEMA size). Consequently, they have a lower rise of the inrush current
in comparison with the European 50Hz asynchronous motors.

India
The Bureau of Indian Standards (BIS) has released updated energy-
efficient motor standards (IS12615:2011) that align with EU regulations:
“The efficiency performance values of motors under the scope shall be
IE3 only and shall be effective from 31 January 2014. However, when these
motors are used with variable frequency drives, they shall conform to
IE2 values of efficiency.”

China
The Chinese government published standard GB18613 setting the energy-
efficiency requirements for general-purpose motors. It was updated in
2012 to more closely align with IEC 60034-30-1.

Other countries
Australia, Korea, Brazil, Mexico, Taiwan, Costa Rica, Israel, and New
Zealand are among the other countries that have taken steps to improve
motor efficiency through more stringent regulations.

IE2: Brazil IE3: EU, 2

IE2: US & Canada IE2: S. Korea, 2 IE3: Japan

IE2: Mexico IE3: US

IE2: Australia IE2: EU, 1 IE3: China

(GB2)
IE1: China IE3: Canada

IE2: Turkey IE3: EU,

3

IE2: IE2: China

S. Korea, (GB3)
1
97

04

05

06

07

08

09

10

12

15

16

17
1

1
19

20

20

20

20

20

20

20

20

20

20

20

20

20

20

Figure 3. Worldwide, countries are tightening their motor-efficiency requirements.

Source www.eemods15.info

schneider-electric.com/TeSys July 2017 | 9

2. What you need to know about
asynchronous motors before
you choose
Robust and reliable, asynchronous (or induction) motors represent 95%
of the worldwide installed motor base. Therefore, the protection of these
motors is a matter of great importance in numerous applications.

2.1. Direct on line (DOL) starting of induction motors l

Different starting methods can be employed for asynchronous motors, lpeakRMS ≈

the simplest of which is direct on line (DOL) starting. Depending on the 8 to 16* ln

protection level and the components used, a DOL motor starter usually
consists of a circuit breaker, a contactor, and an overload relay for ld ≈

protection. 5 to 9* ln

ln
Advantages Disadvantages t
20-30 ms Td≈ 0.5-10 s
• Simple • May not be suitable for use with high-
torque motors Figure 4. Direct on-line starting current for the average
• Low purchase price
• Must be carefully selected to avoid induction motor (super-premium IE4 motors).
• Good starting torque
nuisance tripping during starting

Table 3. DOL motor starter advantages and disadvantages.

You will find more information about asynchronous motors and their
different protection and control methods below. To go further, please refer
to Schneider Electric’s Electrical Installation Wiki: http://www.electrical-
installation.org/enwiki/Asynchronous_motors_(full_page).

2.1.1. Inrush current

High-power asynchronous motors directly connected to the line will draw

high start-up current (see Fig. 1), which is mostly reactive. Figure 1 shows
a typical starting RMS current curve for an asynchronous motor in a direct
on line connection. In general the motor draws current in three steps:
• During the first 20ms to 30ms: shortly after starting, a high peak current
(inrush), symbolized here as “Ipeak”, is observed.
• Between inrush and 0.5s to 10s (depending on rated power and
inertia), a steady-state current called LRC (here abbreviated as Id)
is seen. This current remains constant as long as the rotor just starts
revolving; its duration depends on the motor’s load and design.
• After 0.5s to 10s: the rotor accelerates and reaches its final speed. the
current stabilizes to reach the motor’s nominal current (In) at full load.

schneider-electric.com/TeSys July 2017 | 10

2.1.2. Protection for DOL starters

The most common way of building DOL starters is by combining a circuit

breaker, contactor, and overload relay (Figure 5). This system offers
several advantages. Installation, operation, and maintenance are relatively
simple (components are easier to replace than fuses) and high uptime
is ensured thanks to immediate restarting (when Type 2 coordination is
selected). The system can be controlled remotely and is compatible with
mechanical and electrical interlocks. Motor manufacturers usually provide
tables to facilitate the selection of these components.

Circuit 1.05 to 1.20 In

breaker

Magnetic Operating curve of thermal relay

relay End of
start-up
period
Motor starting current

Contactor Cable thermal withstand limit

1 to
Thermal 10 s
relay

Limit of thermal relay constraint

Cable Short circuit current breaking capacity
of the association (CB + contactor)
Operating curve of the MA type
Motor
20 to circuit breaker
30 ms I
In Is I magn.
Short circuit current breaking capacity
of the CB

Figure 5. Tripping characteristics of a circuit-breaker, contactor, and thermal relay

protection system.

However, before you choose, it is important to understand how premium-

efficiency motors behave differently during starting than previous-
generation motors. Most notably, improvements in motor design have
resulted in changes to inrush current and locked rotor current.
The following section outlines the main changes and explains how they
affect your choice of circuit-breaker, contactor, and thermal relay.

schneider-electric.com/TeSys July 2017 | 11

2.2. Premium-efficiency motors
2.2.1. Design characteristics

The new premium-efficiency motors have several new design

characteristics with regard to previous generation motors:
• Lower stator and rotor resistances
• Longer motor length
• Improved silicon steel and lamination for better magnetization and lower
eddy currents
• Reduced air gap for lower magnetic resistance
• Various improvements in rotor design, bearings, and cooling to reduce
other losses

IE4 motors are coming on the market, the trend toward higher inrush peak
and starting current is clear, and will continue as more efficient motors
penetrate the market. The following table provides typical values.
However, due to different design characteristics, there are large variations
between one motor and another, even for the same rated power.

Parameter Typical value for IE1 motors Typical evolution from IE1 motors
to IE3/IE4 motors
Rated current Ie,rms Depends on rated power 5 to 10%

Locked rotor current ratio + Id /In Motors < 15kW: 6 or less times Id/In +10 to +30%
Motors 15–55kW: 6 or less times Id/In +10%
Motors >55kW: ~7 + 4%

Starting time tstart Depends on torque Expected to decrease, but marginal

effect in practice
Inrush current factor 1.2 to 1.4 +30 to +50%
k =Ipeak /Id
Steady-state temperature Depends on class Temperature rise decrease and fan
size reduced

Table 4. Differences in motor behavior from IE1 to IE3/IE4 motors.

schneider-electric.com/TeSys July 2017 | 12

 0
-0,05 0,00 0,05 0,10 0,15 0,20 0,25 0,30 0,35 0,40 0,45
-2

-4 -4,04
-5,16 -5,24 -5
-6
2.2.2. Premium-efficiency motor current load
Phase 1 (A)
15,0
IE3 premium motors are more energy efficient than IE2 motors. 10,0
9,8 9,0 Phase 2 (A)
7,4
Phase 3 (A)
In Figure 6, IE3 motors have an higher inrush current and an 5,0 higher
1,0
starting current but in full run will have a lower current consumption
0
-0,05 0,00 0,05 0,10 0,15 0,20 0,25 0,30 0,35 0,40 0,45
than IE2. Figure 6 is a simplified version of Figure 7 made-5,0 after some
measurement on physical motors in our laboratory. -10,0
-9,9
-7,1

-15,0

l peak
In peak
Phase 1 (In)
20,0
lE3 peakRMS ≈ 14,1 Phase 2 (In)
15,0 12,9
9 to 16* ln 10,6 Phase 3 (In)
lE3 RMS 10,0
starting current
5,0
1,0

lE3 lLRC 0
-0,05 0,00 0,05 0,10 0,15 0,20 0,25 0,30 0,35 0,40 0,45
lE2 lLRC -5,0
lE2 RMS
-10,0
starting current
-10,3
lE2 IFLC -15,0 -14,0
ln
Seconds
lE3 IFLC -20,0

Figure 6 Figure 7

This higher inrush current has a potential impact on the performance

of protection and control products due to the fact that the locked rotor
current increases the thermal stress on all devices, risking untimely
thermal tripping of circuit breakers and relays. The high peak of the inrush
may also lead to circuit breaker nuisance tripping.

Motor manufacturers usually state the locked rotor current as an Id/In ratio.
However, it is hard to know in advance how high the initial peak of the
inrush–important information when selecting the right circuit breakers–
will be.

The ratio between the highest inrush peak and the locked rotor current
is commonly called the kappa ratio (k) and its order of magnitude is on
average between 1.4 and 1.6 for IE3 motors; it can be as high as 2.0 for
very high torque according to IEC 60034-12. The kappa ratio is calculated
as follows:

k = Ipeak ≅ 1.4 → 2.0

Locked Rotor Current

schneider-electric.com/TeSys July 2017 | 13

 2.2.3. The influence of efficiency on locked rotor current

Some manufacturers do offer super-premium-efficiency (IE4) motors

following standard IEC 60034-30-1. IE2 motors on the market that have
LRCs superior to 8In, similar to the performance achieved by IE3 motors.
Depending on the motor manufacturer, it is possible to purchase an
IE2 motor that has a LRC superior to 8*In.

Figure 7 shows the statistical distribution of 50 Hz motors available on

the market by stated efficiency (according to manufacturers’ catalogue
information). As efficiency improves, LRC increases. Therefore, all of the
components in a motor protection system will need to be assessed to align
with the move towards higher motor efficiency standards. In all cases,
it is highly recommended to follow the manufacturer’s instructions and
recommendations to avoid nuisance tripping–and downtime–due to higher
starting currents.

20%
lE3 lE4
lE2
Product distribution

15%
lE1
10%

5%

4 5 6 7 8 9 10
ld/ln

Figure 7. Statistical distribution of locked rotor current according to manufacturer

catalog specifications.

Expected LRC will also depend on the motor’s rated power.

Figure 8 shows the average LRC of motors for ratings from 0.2 kW
to 400 kW depending on motor efficiency. For IE3 and IE4 motors the
increase in starting current ranges from 16% to 32% for motors rated
between 0.75 kW and 100 kW, currently the most common motor
ratings on the market.

9
0.75 kW to 375 kW
Average starting current / Rated current

8
24 %
lE4 7%
32 %
7
16 %
(Id/In)

6
20 %
lE3
5 lE2

4
lE1

3
0,1 1,0 10,0 100,0
Motor’s rated power (kW)
Figure 8. LRC and rated power.

schneider-electric.com/TeSys July 2017 | 14

2.2.4. The influence of the electrical installation on starting current
and inrush peak current

Certain characteristics of the electrical installation can influence the

current consumed by the motor during the starting phase. The following
are the most relevant ones to take into account when using premium-
efficiency motors:
• Cable length and cross section: a limited cross section (a cable not
over-dimensioned for the motor’s In) would limit the peak that can run
through the cable; this is also true of longer wire lengths.
• Rotor position: when starting the motor, the physical position of the rotor
with regards to the stator can influence the magnitude of the inrush
peak.
• Power factor: a low power factor is caused by any inductive/reactive
load and will have a negative impact on the whole electrical installation;
this problem can be diminished by the use of capacitors.
• Electrical angle.
• Motor brand.
• Rating, oversizing motor rating can lead to higher inrush at startup.

schneider-electric.com/TeSys July 2017 | 15

2.3. Selecting the right protective devices
As stated above, the most common way of protecting DOL starters is
by combining a circuit breaker, contactor, and thermal relay. A magnetic
or thermal-magnetic circuit breaker provides short-circuit protection
and breaking to avoid damage to the installation. A thermal relay detects
overload currents and shuts the motor down before overheating has a
chance to damage the insulation. A contactor is used to control the motor,
providing on/off switching. Choosing the right devices and knowing which
devices to use in combination is crucial.

2.3.1. Circuit breaker and thermal relay

As described above, as starting current increases, so does the risk

of nuisance tripping. Figure 9 shows the hypothetical case of a
suboptimal circuit breaker and thermal relay. The green curve shows the
starting current of an IE2 motor, and the red curve, its IE3 version. If the
values between the motor's starting current and the equipment's threshold
are too close to each other, using the IE2 configuration for the IE3 motor
may result in nuisance tripping and downtime. This depends on the motor
technology, the electrical equipment brand, and correct installation
of all electrical wiring, devices, and equipment.

To select the right circuit breaker and overload relay, you should:
• Follow the recommendations of your motor protection manufacturer.
• Avoid over-dimensioning cable sections.
• Verify that the electrical characteristics stated by the motor
manufacturer are in accordance with the motor starters used.
• Verify the coordination of the motor starter components if there are
selected separately, without using a recommended coordination tables.

Schneider Electric TeSys circuit breakers and thermal relays

have undergone magnetic, electrical, and thermal endurance testing
in laboratory conditions to ensure their compatibility with IE3 motors.
After further tests, the compatibility with IE4 motors has been also verified.

lE3 ln FLC

T(s)
IE3 current

Thermal relay

Td
(0.5 to 30s)
IE2 current Locked Rotor Current

Short-circuit
protection
(magnetic
Td circuit breaker)
(0.010 to
0.015s)

I(A)
lE2 l FLC lE2 l LRC lE2 l PEAK

lE3 l LRC lE3 l PEAK

Figure 9. In the red zone: nuisance tripping with IE3 motors.

schneider-electric.com/TeSys July 2017 | 16

2.3.2. Contactor

A contactor is an electromechanical device designed to switch the current

in an electrical circuit on and off. The maximum breaking current
of a contactor is often given as a ratio of the nominal current: In.
For standard applications, a contactor rated 12 In for closing and 10 In
for opening is sufficient. But for IE3 or IE4 motors, the contactor should be
able to break and make even during the higher inrush peak at startup
to avoid harm to people or equipment.

Schneider Electric TeSys D contactors can sustain up to 20 In equivalent

Rms breaking and making capacity and are suitable for IE3 or IE4 motors.
TeSys contactors have been successfully tested for compatibility with IE3
or IE4 motors.

2.3.3. Coordinating the circuit breaker and contactor

Schneider Electric recommends the following combinations of circuit

breaker and contactor. Note that upgrading from an IE2 to an IE3 or IE4
motor does not change the recommended combination.

Motor type IE2 motor: 5.5 kW IE3 motor: 5.5 kW IE4 motor: 5,5 Kw

Breaker and contactor GV2ME16 + LC1D25 GV2ME16 + LC1D25 GV2ME16 + LC1D25

These combinations are stated in the TeSys 2017 catalogue

MKTED210011EN and can be used for IE3 / IE4 motors without restriction.

schneider-electric.com/TeSys July 2017 | 17

3. Getting started with TeSys
by Schneider Electric

Schneider Electric’s TeSys motor starter range will help you make the
transition to more energy efficient motors with total peace of mind.
TeSys products are fully compatible with IE3 and IE4 motors as confirmed
in laboratory testing for magnetic, thermal, and electrical endurance.
Using TeSys circuit breakers, contactors, and thermal relays ensures
optimal energy efficiency for your installation and compliance
with the latest regulations.

You can also stay up to date on the latest TeSys news

at www.schneider-electric.com/tesys.

TeSys Quick Selector is available to make motor starter selection fast,

simple, and effective

• Quick selection of TeSys motor starter most common combinations

• Motor rated power up to 75 kw
• For Smartphone & tablet

Flash the QR code and update your app!

schneider-electric.com/TeSys July 2017 | 18

References
[IEC 60034-12] IEC 60034-12 standard – Starting performance of single-speed three-phase cage induction
motors – Edition 2, 2002. Revision pending.
[IEC 60947-4-1] IEC 60947-4-1 standard – Low-voltage switchgear and controlgear – Part 4-1: Contactors and
motor-starters – Electromechanical contactors and motor-starters – Edition 3, 2009, revision
pending.
[EN 50598-1] EN 50598-1 standard – Ecodesign for power drive systems, motor starters, power electronics
& their driven applications -- Part 1: General requirements for setting energy efficiency standards
for power driven equipment using the extended product approach (EPA), and semi analytic
model (SAM) – Edition 1, 2015.
http://www.umweltbundesamt.de/en/press/pressinformation/energy-efficiency-in-electric-motors
http://www.nema.org/Policy/Energy/Efficiency/Pages/NEMA-Premium-Motors.aspx
http://www.nema.org/Policy/Energy/Pages/Energy-Legislation.aspx
http://www.bis.org.in/qazwsx/cmd/CMD-1(BD)_22092014.pdf
[IEC 60034-30-1] IEC 60034-30-1: 2014 - Rotating electrical machines - Part 30-1: Efficiency classes of line
operated AC motors (IE code)

schneider-electric.com/TeSys July 2017 | 19

schneider-electric.com

Authors: Adrian FRANCO / Pierre DEHAUT

July 2017

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07/2017 - EDCED115066EN - TeSys motor efficiency (IE3 IE4 compliant) white paper