Guide for the Selection and Application of Energy-efficient Motors

Martin Doppelbauer
IEC WG31
SEW Eurodrive GmbH&Co KG, Germany
Abstract
The latest developments and contents of the IEC project 60034-31: Guide for the selection and
application of energy-efficient motors including variable-speed applications are presented. Currently
the paper is still under development. The final draft will be published in autumn 2009. The official
publication of the technical specification is expected for early 2010.
Introduction
Based on a new work item proposal (NWIP) issued by the German national committee DKE K311,
working group 31 was established in 2006 by the IEC TC 2 (Technical Committee 2 =Rotating
machinery) and assigned the task to define energy efficiency classes for three-phase industrial
motors.
The first meeting of WG31 took place in October 2006. Already at the second meeting in May 2007 it
became clear that more user guidance for energy efficient operation of electric motors and
applications was useful than could be provided in a classification standard.
The idea to create an energy efficiency guide was presented at the general IEC TC2 meeting in May
2007 where the project was confirmed and started.
Until now, two more meetings of WG31 have taken place and the second draft (2CD) of the paper has
been released in April 2009. The final draft paper for voting (DTS) is expected for the end of 2009 and
the finished guide should be available early in 2010.
The guide provides a guideline on technical aspects of the application of energy-efficient, three-
phase, electric motors. It applies to motor-manufacturers, OEMs (original equipment manufacturers),
end-users, regulators, legislators and all other interested parties.
The paper is applicable to all electrical machines covered by IEC 60034-30. Most of the information,
however, is also relevant for synchronous motors and cage induction machines with output powers
exceeding 375 kW. Some sections of the guide were specifically written for variable speed, frequency-
converter operated motors.
The guide is partly based on a paper of the US-American Association of Electrical and Medical
Imaging Equipment Manufacturers (NEMA MG10).
Saving Energy with electrical drive systems
It is a well known fact that electric motors are energy converters. They can only save a part of their
own energy consumption which is only a small part of the total energy they pull from the grid. The
green bars in figure 1 are the electrical energy being converted to mechanical energy and the red
bars are the own consumption (losses) of the motor. The total energy input of the IE1 motors is set to
100% respectively.
2
0
10
20
30
40
50
60
70
80
90
100
IE1
1,1kW
IE2
1,1kW
IE3
1,1kW
IE4
1,1kW
IE1
11kW
IE2
11kW
IE3
11kW
IE4
11kW
IE1
110kW
IE2
110kW
IE3
110kW
IE4
110kW
Ploss[%]
Pout[%]

Figure 1. Comparison of energy usage of 4-pole motors of different sizes and energy-efficiency
classes; Red bars = own consumption, green bars = transferred energy

Obviously, electrical drive systems can save most energy when the whole picture (the complete
application) is taken into account, i.e., when the transferred energy (green bars) is reduced as well.
This includes variable speed control, mechanical elements and ultimately the production-processes
and machines:

Electrical
components
Mechanical
components
Factory
Automation
Energy
Recouperation
S
1
C
o
n
t
i
n
u
o
u
s
D
u
t
y
S
2
S
h
o
r
t

T
i
m
e
S
3
.
.
.
S
1
0
I
n
t
e
r
m
i
t
t
e
n
t

D
u
t
y
Energyefficiency
motors
Powerfactor
correction
devices
Use most economical
components
Consider
rotating
inertia
Variable
speed drive
systems
Properandregular maintenance
Application
Variable
speed drive
systems Softstart
with frequency
control
Mostefficient
powersupply
Mostefficient
powersupply
Lowenergy
modeduring
standstill
Lowenergy
modeduring
standstill
Optimized mass
and flow
Energyefficient
gearboxes,
belts,...
Energyefficient
pumps,fans,
compressors,...
Reducing elec.
transmission
losses
Regenerative
braking
DClink
coupling
Batteries,
ultracaps,
flywheels etc.

Figure 2. Overview of different areas for saving electrical energy with drive systems
3
The duty type of the application plays a major part in determining what amount of energy can be
saved and which strategy is best.
Applications running in continuous duty (S1) are the best candidates for saving energy. They typically
operate between 8 and 24 hours per day and between 250 and 365 days per year.
Motors with higher energy efficiency classes (IE2 or IE3) are very beneficial.
An improved power factor (by using frequency-converters and synchronous motors) can help to
reduce IR losses in the cables. Also field converters, which are installed close by the motor with short
cables, may be helpful to reduce IR losses.
Mechanical optimizations (gearboxes, belts, pumps, fans etc.) may lead to much greater savings than
improvements of the electrical motor alone. However, such measures will often require a significant
reconstruction of the application.
The application itself must be regarded as well. In many cases variable speed control can be utilized
to reduce the energy consumption during light-load periods.
Many industrial plants have a high energy consumption of the low voltage control circuits (typically
24V power supply). Therefore, high-efficiency low-voltage power supply modules should be used. If
possible, the factory should be shut down during longer standstill periods (weekends, holidays).
Applications running in short-time duty (S2) are usually not suitable for energy-saving measures. Due
to the short running time they do not consume enough energy to justify costly measures. Typical
examples are gate or garage door openers, valve controllers, emergency pumps and fans etc.
Intermittent duty applications (S3-S10) have to be regarded on a case-by-case basis. Typical
examples are cranes, hoist drives, lifts etc.
Some of these applications are powered directly from the grid and are switched by simple circuit
breakers. They may have high switching frequencies (up to several cycles per minute). In these
cases, high-efficiency electrical motors may be counterproductive and consume even more energy
than standard-efficient motors due to their increased inertia and start-up currents. High-efficient
motors will also increase the wear of electromechanical brakes which are frequently used in such
applications.
In some extreme cases it might be technically impossible to run the application with high-efficiency
motors at all.
Other intermittent duty applications are powered by frequency converters. The converter will reduce
the start-up losses considerably and therefore save energy compared to grid operated motors. A
higher efficiency of the motor may not improve the overall picture much (or even worsen the situation
due to the increased inertia).
Often, just like short-time duty applications, the actual running time of intermittent duty applications is
relatively low.
Some intermittent duty applications, where the cycle frequency is rather low and the running time
rather high, will benefit from motors of improved efficiency, for example passenger and goods lifts.
Retrofitting existing applications with high- and premium-efficient motors
Due to the fact that cage-induction motors with a high energy-efficiency contain more active material
(copper, iron) than their lower efficient counterparts the torque over speed characteristic of these
motors is normally stiffer, i.e. the nominal operating speed is higher (see figure 3).

4
0
50
100
150
200
250
1000 1100 1200 1300 1400 1500
T
o
r
q
u
e

[
N
m
]
speed[1/min]
IE1
IE2
IE3
SquareLoad

Figure 3. Exemplary torque over speed curves for three 4-pole, 11 kW, induction-motors with
different energy-efficiency classifications and fan load curve
Note: Due to the scale of the graph and the suppression of speeds below 1000 rpm the black-curve appears to be linear
although it is actually a square-load curve.
This can be a potential pitfall when the driven load-machine has a torque characteristic that increases
with the square of the speed (typical for all types of fans, compressors and pumps) (see figure 4).
50
60
70
80
90
100
1450 1455 1460 1465 1470 1475 1480 1485 1490 1495 1500
T
o
r
q
u
e
[
N
m
]
Speed[1/min]
IE1
IE2
IE3
SquareLoad

Figure 4. Zoomed torque over speed curves for three 4-pole, 11 kW, induction-motors with
different energy-efficiency classifications and fan load curve
Note: Due to the scale of the graph and the suppression of speeds below 1450 rpm the black-curve appears to be linear
although it is actually a square-load curve.
5
The speed increase is depending on the frame-size, number of poles and electromagnetic design of
the motor so a general rule cannot be given.
For a typical 4-pole motor series between 0,75 kW and 55 kW a speed increase of 1,1% from IE1 to
IE2 and a further 0,5% increase from IE2 to IE3 has been found in average.
The higher speeds translate to an average increase in power demand of square-torque loads
compared to the next lower efficiency class of 3,4% and 1,6% for IE2 and IE3 respectively.
This power increase may not seem much but is has to be related to the reduction of losses per
efficiency class which is also just a small fraction of the output power.
Figures 5 and 6 give a comparison of the reduction of losses (green bars) in watt compared to the
theoretical increase in load demand (red bars) when load is a square of the speed (not taking
additional effects like friction or temperature into account).
The figures were derived from motor data of an actual 4-pole motor series of one manufacturer and
are not universal for all types of motors or all manufacturers.

250
0
250
500
750
1000
0,75 1,1 1,5 2,2 3 4 5,5 7,5 11 15 18,5 22 30 37 45
L
o
s
s
e
s

[
W
]
Nominalmotoroutputpower[kW]
IE2comparedtoIE1
Lossreductiondueto higherefficiencyclass
Powerdemandincreasedueto speedincrease

Figure 5. Exemplary reduction of losses of 4-pole IE2 motors compared to IE1 motors and
increase of power demand in square torque applications (fans, pumps, compressors)

6

250
0
250
500
750
1000
0,75 1,1 1,5 2,2 3 4 5,5 7,5 11 15 18,5 22 30 37 45
L
o
s
s
e
s

[
W
]
Nominalmotoroutputpower[kW]
IE3comparedtoIE2
Lossreductiondueto higherefficiencyclass
Powerdemandincreasedueto speedincrease

Figure 6. Exemplary reduction of losses of 4-pole IE3 motors compared to IE2 motors and
increase of power demand in square torque applications (fans, pumps, compressors)
In reality, the saved energy is just the difference between the red bars and the green bars. Whenever
the red bars exceed the green bars the energy-efficient motor actually consumes more energy than
the lower-efficient motor. Of course it also runs faster and produces more flow. But that might not be
the desired goal.
In general, the speed and output-power increase associated with the selection of motors of a higher
energy efficiency class may reduce or, in some cases, actually reverse the benefit of the efficiency
improvement in fan, compressor and pump applications.
A variable frequency converter can be used to reduce the speed to a lower level. But a converter is a
costly device and will also add further losses to the system. For these reasons, frequency converters
should not be used in full-speed, full-load applications just for the purpose of constant speed
reduction alone.
Only in applications where a variable speed is beneficial anyhow and/or where longer periods of part-
load operation are common, a frequency converter will be a viable alternative.
Otherwise the only solution to avoid the increased losses of higher speed motors may be to
mechanically reconstruct either the fan, compressor or pump (smaller blades or impellers etc.) or to
adapt the conduit system to utilize the higher speed for the same mass flow (larger cross-sections,
increased turning radiuses etc.).
Interpolation of part-load losses
Most manufacturers give the efficiency for full load and three-quarter load in their catalogues.
In order to calculate the savings of an application a detailed knowledge of part-load efficiencies may
be beneficial. For these cases the guide gives a simple set of formulas which can be used with good
accuracy to interpolate any part-load efficiency (chapter 5.5).
The formulas are based on universal physical properties of three-phase rotary-field motors and can be
used for induction- and synchronous-machines alike:
7
p
p
L
p
L
L
+ +
=

0
100
0
75 100
1
1
1
1
4375 . 0
1
1
75 . 0 1
1

with:

100
=Efficiency at rated load (from 0...1 with 1 equals 100%)

75
=Efficiency at 3/4 load (from 0...1 with 1 equals 100%)

L
,
0
=Intermediate results
p =Desired power (relative to rated load, i.e. from 0...1...overload)

p
=Resulting efficiency (from 0...1 with 1 equals 100%)
Super-Premium Efficiency IE4
Already very early on in the project working group 31 decided to add a further energy efficiency class
for industrial motors to the established Standard- (IE1), High- (IE2) and Premium-Efficiency (IE3)
scheme.
The new class was intended to unify the historical differences of 50 Hz and 60 Hz countries and also
to broaden the application range to all kinds of industrial motors including frequency converter driven
motors like permanent-magnet synchronous-types.
For that reason it was decided to base the new levels on speed classes and output torque rather than
on number of poles and output power.
It became clear that further harmonization would be needed and so the specifications for IE4 were
moved from the classification standard IEC 60034-30 into the guide IEC 60034-31 as an informative
annex. At the next revision of IEC 60034-30, when more experience is available, an updated definition
of IE4 shall be pulled back into the standard.
Figure 7 gives an overview of the new limiting curves as published in the second CD of IEC 60034-30.
8

75
80
85
90
95
100
0 500 1000 1500 2000 2500 3000 3500 4000
E
f
f
i
c
i
e
n
c
y

[
%
]
Speed
[1/min]
NominalIE4efficiencylimitsforselectedtorques[Nm]
2000
800
250
100
40
16
6,3
2,5

Figure 7. IE4-efficiency limits
The curves are a compromise of different goals.
In average, the reduction of losses of IE4 should be some 15% compared to IE3.
Practically, this could only be reached in relation to the 60 Hz IE3-curve with 16.6%, 16.5% and
16.2% difference in average losses for 2-, 4- and 6-pole machines respectively.
Due to the generally smaller size of 50 Hz IEC motors compared to 60 Hz NEMA motors and the
energetic disadvantages of 50 Hz versus 60 Hz, the IE3 limits for 50 Hz motors are lower than for 60
Hz motors and so the difference to the frequency independent IE4 class must be bigger.
In the current draft the differences in losses of 50 Hz 2-, 4- and 6-pole machines of efficiency class
IE4 compared to IE3 are in average 22.6%, 26.9% and 19.5% respectively.
For small motors it is typical to reach the highest efficiency at high output speeds around 3000 to
5000/min. For larger motors, the peak efficiency is reached at lower speeds. The IE4 curves model
this physical characteristic in principle. They can of course never be exact as this phenomenon is
depending on many individual motor design parameters, most importantly on the type of ventilation.
In order to maintain compatibility with the existing IE1, IE2 and IE3 curves and to simplify the
application of the new class to conventional three-phase, cage-induction motors, additional tables are
given in the standard with references to output power, grid frequency and pole-number (see figures 8
and 9).
These tables however are derived from the original torque/speed/efficiency table which remains the
normative basis.
9

80
85
90
95
100
1 10 100 1000
[
%
]
[kW]
4pole
IE4 SuperPremium Efficiency60Hz
IE4 SuperPremium Efficiency50Hz
IE3 PremiumEfficiency60Hz
IE3 PremiumEfficiency50Hz
IE2 HighEfficiency60Hz
IE2 HighEfficiency50Hz
IE1 Standard Efficiency60Hz
IE1 Standard Efficiency50Hz

Figure 8. Efficiency limits for 4-pole cage-induction motors related to output power

7
8
7
8
78
78
8
0
8
0
80
80
8
2
8
2
82
82
8
4
8
4
84
84
8
6
8
6
86
86
8
8
8
8
88
88
88
9
0
9
0
90
90
90
9
2
92
92
92
92
92
92
9
4
9
4
94
94
94
94
94
9
6
9
6
96
96
96
96
96
9
6
n [1/min]
M

[
N
m
]
IE4 limits [%]


1000 1500 2000 2500 3000 3500
10
1
10
2
10
3
78
80
82
84
86
88
90
92
94
96

Figure 9. Efficiency limits for IE4 motors in relation to nominal motor torque and nominal
speed
It must be noted that IE4 only gives efficiency limits for the nominal motor speed and nominal motor
torque. If motors are rated for a speed range (and possibly a nominal torque range) then the limits of
IE4 must be reached for all ratings.
10
On the other hand, when a motor is operated at partial load it does not need to reach the efficiency
defined in IE4 for that particular torque.
The efficiency is always tested between the motor input terminals (winding connection wires) and the
mechanical output (shaft). Losses in cables and converters as well as losses in external devices like
electromechanical brakes, clutches, speed encoders, external fans etc. are not taken into account for
the classification according to IEC 60034-30 and -31.
The energy-efficiency classes IE1, IE2 and IE3 as defined in the current edition of IEC 60034-30 may
only be applied to three-phase, cage-induction motors within the specified voltage and power range.
These classes are not applicable to any other types of motors.
Only the efficiency class IE4 as defined in the current draft of IEC 60034-31 may be applied to all
kinds of low-voltage electric motors within the specified nominal output torque and speed range.
Conclusion
The drafted new IEC 60034-31 application guide gives background information for the application of
energy efficient motors and drive systems. It is useful for regulators, manufacturers, end-users and
OEMs. While some of the material is very technical and aimed at manufacturers and OEMs (like
converter losses, power factor improvements etc.) other information is also relevant for regulators and
end-users.
The important topics covered include applications running under partial load and/or in part time,
replacement of standard motors by energy-efficient motors in square-load type applications, additional
losses introduced by electronic frequency converters, effects on power-factor, comparison of 50 Hz
and 60 Hz grid frequency, starting performance, voltage unbalance and the introduction of a new
efficiency class (IE4) for all types of electrical machines and not just cage-induction motors.
For a large number of different types of applications the guide gives specific tips and tricks regarding
important features to look after.
References
[1] IEC 60034-30 (2008-10): Rotating electrical machines Part 30: Efficiency classes of single-
speed, three-phase, cage-induction motors (IE-code)
[2] IEC 2/1554/CD (2009-04): IEC 60034-31: Rotating electrical machines Part 31: Guide for the
selection and application of energy-efficient motors including variable-speed applications