inventions

Article
IEC61800-9 System Standards as a Tool to Boost
the Efficiency of Electric Motor Driven
Systems Worldwide
João Fong *, Fernando J. T. E. Ferreira , André M. Silva and Aníbal T. de Almeida
Department of Electrical Engineering and Computers, Institute of Systems and Robotics, University of Coimbra,
3030-290 Coimbra, Portugal; ferreira@deec.uc.pt (F.J.T.E.F.); ams.sete@gmail.com (A.M.S.);
adealmeida@isr.uc.pt (A.T.d.A.)
* Correspondence: joaofong@isr.uc.pt; Tel.: +351-239796315




Received: 12 March 2020; Accepted: 13 May 2020; Published: 20 May 2020


Abstract: Recognition of the energy savings potential in motor driven systems has led to the
development of energy efficiency testing and classification standards for motors and end-use
equipment (e.g., pumps and fans) and the implementation of minimum energy performance
regulations targeting them worldwide. However, these standards and regulations have been limited to
components, disregarding the interaction between them. The energy savings achievable by addressing
and improving the entire system are potentially much higher in relation to those achievable when
considering individual components. Recently, an effort to develop standards in this regard was
carried out by standardization bodies (IEC and ISO) leading to the publication of the IEC61800-9
Power Drive System standard series. The paper, in its first part, describes recent evolutions in electric
motor energy-efficiency standards and in the implementation of related regulations worldwide.
In the second part of the paper, using the latest energy efficiency test and classification standards,
a comparative analysis of different energy-efficient motor technologies is presented. Using results
from laboratory tests combined with data provided by manufacturers, different power drive systems
are compared considering different operating points in two typical pumping systems. Estimated
economic savings from a total cost of ownership perspective are presented.

Keywords: electric motors; electric motor systems; power drive systems; energy efficiency; extended
product approach; minimum energy performance standards

1. Introduction
The International Energy Agency (IEA) states that energy efficiency alone could provide more
than 40% of the reduction in greenhouse gas emissions required by 2040 to reach the climate goals and
be in line with the Paris Agreement [1].
In the industrial sector, the largest potential for reduction in electricity consumption and
corresponding emissions results from improving the efficiency of electric motors and end-use devices
(e.g., pumps and fans), as well as the use of better system/process control strategies. Today, in industry,
electric motor systems account for 70% of the electricity demand [2]. The acknowledgement of this
potential major contribution has led to the introduction of regulations imposing minimum energy
efficiency levels for new electric motors in all major economies. In Figure 1, the latest minimum energy
performance standards (MEPS) adopted worldwide for electric motors can be seen.

Inventions 2020, 5, 20; doi:10.3390/inventions5020020 www.mdpi.com/journal/inventions

 Inventions 2020, 5, x FOR PEER REVIEW 2 of 15

energy
Inventions 2020,efficiency
5, 20 levels for new electric motors in all major economies. In Figure 1, the latest2 of 15
minimum energy performance standards (MEPS) adopted worldwide for electric motors can be seen.

Figure 1. Minimum energy performance standards worldwide for electric motors.

Figure 1. Minimum energy performance standards worldwide for electric motors.
2. International Testing and Classification Standards
2. International Testing and Classification Standards
Over the past decades different regional or national standards for efficiency classification were
Over the
in use around thepast
world, decades
suchdifferent
as NEMA regional or national
and EPAct in thestandards
USA, CSA for efficiency
in Canada, classification
CEMEP in were
Europe,
in use around the world, such as NEMA and EPAct in the USA,
COPANT in South America, AS/NZS in Australia and New Zealand, JIS in Japan, GB in China and CSA in Canada, CEMEP in Europe,
COPANT in South America, AS/NZS in Australia and New Zealand, JIS in Japan, GB in China and
others, relying on different test methods for the determination of the motor efficiency, which yielded
others, relying on different test methods for the determination of the motor efficiency, which yielded
significantly different results.
significantly different results.
Nowadays, energy efficiency classification for direct-on-line (DOL) electric motors is harmonized
Nowadays, energy efficiency classification for direct-on-line (DOL) electric motors is
by standard
harmonizedIEC by 60034-30-1
standard [3],IECwhich is used
60034-30-1 [3], by
whichmost is countries
used by most as the basis for
countries as their regulations.
the basis for their IEC
60034-30-1 standard defines the motor efficiency classes from IE1 (Standard)
regulations. IEC 60034-30-1 standard defines the motor efficiency classes from IE1 (Standard) to IE4 to IE4 (Super-Premium).
In this standard, an additional
(Super-Premium). class IE5an(Ultra-Premium)
In this standard, additional class IE5 is proposed, but notisdefined.
(Ultra-Premium) proposed, It isbut
thenot
goal to
reducedefined. It is the
the losses goalmotors
of IE5 to reduce bythe losses
about 20%of IE5 motors by
in relation to about
the IE4 20% in relation
class. to the IE4
The standard class.
also The
determines
that, standard also determines
for induction motors, the that,test
for induction
method motors,
used shall the test method used
be “Method shall –
2-1-1B beSummation
“Method 2-1-1B –
of losses,
Summation of losses, additional load losses according to the method
additional load losses according to the method of residual loss” as specified in IEC 60034-2-1 [4], of residual loss” as specified in
IEC 60034-2-1 [4], effectively harmonizing the motor efficiency test method used for regulatory
effectively harmonizing the motor efficiency test method used for regulatory purposes around the world.
purposes around the world.
The United States and Canada were the first countries to implement MEPS, at the IE2 level, in
The United States and Canada were the first countries to implement MEPS, at the IE2 level, in
1997,1997,
which have, meanwhile been raised in 2010 to the IE3 level [5]. Other countries have followed
which have, meanwhile been raised in 2010 to the IE3 level [5]. Other countries have followed
this model, using
this model, using thetheIE2IE2level
levelasasa afirst
firstMEPS
MEPS tier to allow
tier to allowmanufacturers
manufacturers somesometimetime to adapt
to adapt to theto the
market, before
market, raising
before MEPS
raising MEPS to to
IE3.
IE3.The
TheEuropean
European Union Unionhas hasrecently
recentlygonegone a step
a step further,
further, introducing
introducing
MEPSMEPSat IE4at class level
IE4 class forfor
level motors
motors ininthe
the75
75kW–200
kW–200 kW kWpower
powerrange,range, starting
starting fromfrom 2021.
2021. For theForfirst
the first
time,time, efficiency
efficiency requirements
requirements forfor variablespeed
variable speed drives
drives (VSDs)
(VSDs)were were also introduced,
also introduced, at theat IE2
theclass
IE2 class
level level [6]. The
[6]. The VSDVSD efficiency
efficiency classesare
classes aredefined
defined in in the
the IEC61800-9-2
IEC61800-9-2[7]. [7].
New motor applications are increasingly being installedwith
New motor applications are increasingly being installed with VSDs,
VSDs, enabling
enabling speed and torque
speed and torque
control. Motors equipped with VSD are expected to reach over 50% of all sold motors leading to
control. Motors equipped with VSD are expected to reach over 50% of all sold motors leading to
significant energy savings for applications that benefit from partial speed operation.
significant energy savings for applications that benefit from partial speed operation.
This increasing market importance of motors driven by VSDs has led to the development and
This increasing
publication market
of efficiency importance
testing of motors
and classification driven for
standards by motors
VSDs has led toon
operating the development and
a non-sinusoidal
publication
supply,of efficiency
which leads totesting
increasedand losses
classification
in the motorstandards
due tofor themotors operating
non-sinusoidal on a (additional
supply non-sinusoidal
supply, whichlosses):
harmonic leads to increased losses in the motor due to the non-sinusoidal supply (additional
harmonic losses):
• IEC/TS 60034-2-3:2013, Specific test methods for determining losses and efficiency of converter-fed
AC induction motors [8].
• IEC/TS 60034-30-2:2016, Efficiency classes of variable speed AC motors (IE-code) [9].
More recently, the recognition of the importance of the potential energy savings achievable
by addressing the energy efficiency of the entire motor system, instead of regulating individual
Inventions 2020, 5, x FOR PEER REVIEW 3 of 15

• IEC/TS 60034-2-3:2013, Specific test methods for determining losses and efficiency of converter-
fed AC induction motors [8].
Inventions 2020, 5, 20 3 of 15
• IEC/TS 60034-30-2:2016, Efficiency classes of variable speed AC motors (IE-code) [9].
More recently, the recognition of the importance of the potential energy savings achievable by
components, has led to the development of standards that tackle this complex subject [10]. In the
addressing the energy efficiency of the entire motor system, instead of regulating individual
industry sector, efficiency improvement measures for electric motor systems would help to avoid
components, has led to the development of standards that tackle this complex subject [10]. In the
nearly 3100 TWh of electricity consumption by 2040, cutting industrial electricity demand growth by
industry sector, efficiency improvement measures for electric motor systems would help to avoid
nearly half when compared to a “business as usual” scenario. All these measures are cost-effective,
nearly 3100 TWh of electricity consumption by 2040, cutting industrial electricity demand growth by
being based on energy savings alone, and are designed to use technologies that are readily available
nearly half when compared to a “business as usual” scenario. All these measures are cost-effective,
today [1].
being based on energy savings alone, and are designed to use technologies that are readily available
today
3. [1].
Standards at Motor System Level
The use of
3. Standards at VSDs
Motorfor process
System control, matching the output to the demand of the process, can lead
Level
to substantial energy savings in particular in centrifugal fluid motion applications where the power
variesThe
withuse
theofcube
VSDs offor
theprocess control,
speed (e.g., matching
centrifugal the output
pumps to the
and fans). demandthe
However, of the
VSDprocess, can lead
also introduces
to substantial
its energy
own losses and, as savings
referredin particular
before, leadsintocentrifugal
additional fluid
lossesmotion applications
in the motor. where
Therefore, thethe power
analysis
varies with the cube of the speed (e.g. centrifugal pumps and fans). However, the
of VSD-fed motor applications needs to include these losses, measured or calculated at the differentVSD also introduces
its own lossespoints
speed-torque and, as ofreferred
operationbefore,
[11]. leads to additional losses in the motor. Therefore, the analysis
of VSD-fed motor
To support theapplications
introduction needs to include at
of regulations these losses,
system measured
level, IEC hasordeveloped
calculatedtheat the different
IEC61800-9
speed-torque points of operation [11].
standard based on previous work carried out by CENELEC at European level (EN 50598 series).
To support
This standard hasthe
twointroduction
parts: of regulations at system level, IEC has developed the IEC61800-9
standard based on previous work carried out by CENELEC at European level (EN 50598 series). This
•standard
IEC 61800-9-1:2017,
has two parts: Adjustable speed electrical power drive systems—Part 9-1: Ecodesign for
• IEC 61800-9-1:2017,
power drive systems, motor starters,
Adjustable speedpower electronics
electrical and their
power drive driven
systems applications—General
- Part 9-1: Ecodesign for
requirements
power for setting
drive systems, energy
motor efficiency
starters, power standards
electronicsfor
andpower driven applications
their driven equipment using the
- General
extended product
requirements approach
for setting (EPA)efficiency
energy and semi analytic
standards model (SAM) driven
for power [12]; equipment using the
• extended
IEC 61800-9-2:2017, Adjustable
product approach (EPA) speed
and electrical power
semi analytic drive
model systems—Part
(SAM) [12]; 9-2: Ecodesign for
• IECpower drive systems,
61800-9-2:2017, motor starters,
Adjustable speedpower electronics
electrical and their
power drive driven
systems applications—Energy
- Part 9-2: Ecodesign for
efficiency
power indicators
drive systems,formotor
power drive systems
starters, and motor starters
power electronics and their [7].driven applications - Energy
efficiency indicators for power drive systems and motor starters [7].
In Figure 2, the boundaries of the electric motor, complete drive module (CDM; i.e., VSD), power
In Figure 2, the boundaries of the electric motor, complete drive module (CDM; i.e., VSD), power
drive system (PDS = CDM + motor), motor system, driven equipment (DRE, which includes the
drive system (PDS = CDM + motor), motor system, driven equipment (DRE, which includes the
mechanical transmission and the load machine), and extended product (EPR = PDS + DRE), as set out
mechanical transmission and the load machine), and extended product (EPR = PDS + DRE), as set out
in the IEC 61800-9 standard, are shown.
in the IEC 61800-9 standard, are shown.

Figure 2. Boundaries of the complete drive module, power drive system, motor system, driven
equipment, and extended product, as set out in the IEC 61800-9-2 ed.1.0 standard [12]. Copyright ©
2017 IEC Geneva, Switzerland. www.iec.ch.
Inventions 2020, 5, x FOR PEER REVIEW 4 of 15

Figure 2. Boundaries of the complete drive module, power drive system, motor system, driven
Inventions 2020, 5, 20 4 of 15
equipment, and extended product, as set out in the IEC 61800-9-2 ed.1.0 standard [12]. Copyright ©
2017 IEC Geneva, Switzerland. www.iec.ch
The standard defines different boundaries for the level at which the efficiency (or losses) are dealt
with The standard
within defines
its different different
parts (Figureboundaries
3). for the level at which the efficiency (or losses) are
dealt with within its different parts (Figure 3).

Figure
Figure 3. Illustration of
3. Illustration of the
the operating points (shaft
operating points (shaft speed
speed and
and torque)
torque) for
for the
the determination
determination of
of the
the
relative losses of the Complete Drive Module (CDM) and Power Drive System (PDS) as set
relative losses of the Complete Drive Module (CDM) and Power Drive System (PDS) as set in IEC in IEC
61800-9-2
61800-9-2 ed.1.0
ed.1.0 [7]. Copyright ©
[7]. Copyright 2017 IEC
© 2017 IEC Geneva,
Geneva, Switzerland.
Switzerland. www.iec.ch
www.iec.ch.

Part
Part 11 of
of IEC
IEC 61800-9
61800-9 standard
standard specifies
specifies aa methodology
methodology to to combine
combine the the motor
motor system
system data
data with
with
the driven equipment data, in order to calculate the system energy
the driven equipment data, in order to calculate the system energy efficiency for the whole efficiency for the whole application
(extended
applicationproduct).
(extendedThe systemThe
product). efficiency
systemisefficiency
expressedisby an Energy
expressed by Efficiency
an EnergyIndex (EEI)Index
Efficiency for a
defined duty (load-time) profile. It allows the direct comparison of
(EEI) for a defined duty (load-time) profile. It allows the direct comparison of different motor systems, different motor systems, and
to
andperform
to perform optimization
optimization at system
at system level,level,by by selecting
selecting thethe mostmost efficient
efficient drive+ +motor
drive motor++ driven
driven
equipment combination.
equipment combination.
Part
Part 22 of
of IEC
IEC 61800-9
61800-9 standard
standard defines
defines efficiency
efficiency classes
classes for for the
the CDMCDM and and PDS.
PDS. Because
Because motors
motors
driven
driven by VSDs are meant to be operated mainly at part load, eight operating points for testing are
by VSDs are meant to be operated mainly at part load, eight operating points for testing are
given, for the
given, for the CDM
CDM and and PDS,
PDS,as asshown
shownininFigure Figure3.3.ThisThisoperating
operating points
points areare defined
defined bybythethe
pairpair
of
of values (% of rated frequency; % of rated torque) in the case of CDM
values (% of rated frequency; % of rated torque) in the case of CDM and (% of rated speed; % of rated and (% of rated speed; % of
rated
torque)torque)
in the in theofcase
case PDS, of where
PDS, where the percent
the percent frequency
frequency corresponds corresponds
to the to thebetween
ratio ratio between the
the actual
actual supply fundamental frequency and the rated supply frequency
supply fundamental frequency and the rated supply frequency of the motor, the percent speed of the motor, the percent speed
corresponds
corresponds to to the
the ratio
ratio between
between the the actual
actual shaft speed and
shaft speed and the the rated speed of
rated speed of the
the motor,
motor, andand the
the
percent
percent torque corresponds to the ratio between the actual shaft torque and the rated torque of
torque corresponds to the ratio between the actual shaft torque and the rated torque of the
the
motor.
motor. For
For the
the CDM,
CDM, losses
losses are
are measured
measured at at 90%
90% ofof motor
motor ratedrated frequency
frequency to to avoid
avoid overmodulation
overmodulation
in
in the
the voltage-source
voltage-source inverter
inverter PWM PWM output.
output. For For CDM
CDM classification
classification purposes,
purposes, only only thethe losses
losses atat the
the
operating
operating point (90; 100) are considered, hence, the energy efficiency classes are defined basedthat
point (90; 100) are considered, hence, the energy efficiency classes are defined based on on
single operation point.
that single operation point.
For
For the
the determination
determination of of CDM losses three
CDM losses three methods
methods are are specified,
specified, namely,
namely, (i) (i) single
single component
component
loss determination, (ii) input-output measurement, and (iii)
loss determination, (ii) input-output measurement, and (iii) calorimetric measurement. calorimetric measurement.
For
For the
the first
first method
method the the total
total CDM
CDM losses losses willwill bebe determined
determined using using an an analytical
analytical calculation
calculation
procedure, which allows the calculation of losses of a product
procedure, which allows the calculation of losses of a product without measurements without measurements andand
relies on the
relies on
calculation of CDM individual component losses based on parameters
the calculation of CDM individual component losses based on parameters supplied by manufacturers. supplied by manufacturers.
This
This loss
losscalculation
calculationmethod
method includes
includes (i) AC-AC
(i) AC-AC outputoutputconverter losseslosses
converter (transistor ON-state
(transistor losses,
ON-state
freewheeling diode ON-state losses, transistor switching losses,
losses, freewheeling diode ON-state losses, transistor switching losses, and freewheeling diode and freewheeling diode switching
losses),
switching(ii)losses),
AC-DC(ii) or AC-DC
AC-AC or input
AC-ACconverter
input losses
converter(diodelossesrectifier
(diode losses or active
rectifier lossesinfeed converter
or active infeed
losses), (iii) input choke losses, (iv) DC link losses, (v) conductor/cable
converter losses), (iii) input choke losses, (iv) DC link losses, (v) conductor/cable Joule losses; Joule losses; (vi) control module(vi)
losses
controloperation
module losses and standby
operationlosses,
andand standby(vi) cooling loss (vi)
losses, and factor.cooling loss factor.
The
The remaining
remaining two two methods,
methods, input-output
input-output and and calorimetric,
calorimetric, rely rely onon testing.
testing.
Reference
Reference values for the losses of the reference motor (RM), reference CDM
values for the losses of the reference motor (RM), reference CDM (RCDM)(RCDM) and and the
the
reference PDS (RPDS) are laid down for the eight operating points
reference PDS (RPDS) are laid down for the eight operating points and efficiency classes are defined and efficiency classes are defined
for the PDS
for the PDS andandfor forthe
theCDMCDMrelative
relativetotothese thesereference
referencelosses.
losses. The The losses
losses forforthethe
RMRM areare
basedbased on
on the
the IE2 class as defined in 60034-30-1. For the CDM, the standard defines
IE2 class as defined in 60034-30-1. For the CDM, the standard defines three classes, namely, IE0, IE1, three classes, namely, IE0,
IE1,
and and
IE2, IE2,
and and a reference
a reference value value for losses
for losses corresponding
corresponding to IE1to IE1 class
class is defined
is defined forfor each
each power
power size.
size. If
Inventions 2020, 5, 20 5 of 15
Inventions 2020, 5, x FOR PEER REVIEW 5 of 15

If the
the CDM
CDM hashas 25%
25% more
more losses
losses than
than thethe reference
reference value,
value, it will
it will be classified
be classified as IE0.
as IE0. If it at
If it has has at least
least 25%
25% lower losses than the reference, it is classified as IE2, as shown in Figure
lower losses than the reference, it is classified as IE2, as shown in Figure 4. 4.

Figure 4. Efficiency levels and classes for CDM classification defined in the IEC 61800-9-2 standard.
Figure 4. Efficiency levels and classes for CDM classification defined in the IEC 61800-9-2 standard.
For the PDS, a similar reasoning is applied, again with three classes, namely, IES0, IES1, and
For the PDS, a similar reasoning is applied, again with three classes, namely, IES0, IES1, and
IES2, with IES1 as the reference class. The distance to the reference losses is only 20%. IES energy
IES2, with IES1 as the reference class. The distance to the reference losses is only 20%. IES energy
efficiency classes are defined based on the single operation point (100; 100). For the determination
efficiency classes are defined based on the single operation point (100; 100). For the determination of
of PDS losses (and efficiency class), two methods are specified: (i) loss calculation; (ii) input-output
PDS losses (and efficiency class), two methods are specified: (i) loss calculation; (ii) input-output
measurement. The calorimetric measurement method is excluded, as it is difficult to perform on
measurement. The calorimetric measurement method is excluded, as it is difficult to perform on
electric motor systems.
electric motor systems.
Additionally, for the analysis of a particular EPR or PDS, all eight load points, a subset of these
Additionally, for the analysis of a particular EPR or PDS, all eight load points, a subset of these
eight points, or the actual load points of a known application, can be used. For example, points
eight points, or the actual load points of a known application, can be used. For example, points (100;
(100; 100), (100; 50), (50; 25) can be used to estimate the losses in quadratic-torque applications such as
100), (100; 50), (50; 25) can be used to estimate the losses in quadratic-torque applications such as
centrifugal pumps and fans, while points (100; 100), (50; 100), (0; 100) are used for constant-torque
centrifugal pumps and fans, while points (100; 100), (50; 100), (0; 100) are used for constant-torque
applications (e.g., conveyer belts, hoisting machines, and extruders). For constant-power applications,
applications (e.g. conveyer belts, hoisting machines, and extruders). For constant-power applications,
such as winders and winches points (0; 100), (50; 50) and (100; 50) can be used. The standard also
such as winders and winches points (0; 100), (50; 50) and (100; 50) can be used. The standard also
specifies the extrapolation procedure to calculate other intermediate points. For a more accurate
specifies the extrapolation procedure to calculate other intermediate points. For a more accurate
analysis of an individual application, the actual operating points of a PDS (speed; torque) can be used,
analysis of an individual application, the actual operating points of a PDS (speed; torque) can be used,
as well as the duty-cycle profile (load ratio as a function of time).
as well as the duty-cycle profile (load ratio as a function of time).
3.1. The Extended Product Approach
3.1. The Extended Product Approach
The current practice, with the exception of certain clean water pumps in the USA and water
The current
circulators in other practice, withisthe
countries, exception
to regulate theofefficiency
certain clean water pumps
of individual motorin system
the USA and water
components,
circulators
disregarding intheir
otherinteraction
countries,andis tobest
regulate the efficiency
combination. However,of individual motor system
the best approach components,
is to determine and
disregarding
classify the efficiency of the EPR [13], considering the complete integration and interaction of and
their interaction and best combination. However, the best approach is to determine the
classify the efficiency
PDS, mechanical of the EPR(e.g.,
transmission [13], considering
gear, belts, or thedirect
complete integration
coupling) and interaction
and driven of the PDS,
end-use equipment
mechanical
(e.g., pump, transmission (e.g. as
fan, or conveyor), gear, belts,
shown in or direct
Figure 5. coupling) and driven end-use equipment (e.g.
pump, fan, or conveyor), as shown in Figure 5.
Some small products (e.g., circulator pumps, exhaust fans, and cooling compressors) include
the motor, small
Some the VSD,products (e.g.
and the circulator
end-use pumps, exhaust
equipment (pump, fans, and cooling compressors)
fan, compressor, etc.) into oneinclude the
integrated
motor, the VSD, and the end-use equipment (pump, fan, compressor, etc.)
package manufactured by one producer. This facilitates efficiency testing since direct input-output into one integrated
package
method can manufactured by onewith
be easily applied, producer.
the EPR This facilitates
efficiency efficiency
equal testing since
to the mechanical direct
power input-output
output divided
method can be easily applied, with the EPR efficiency equal to the mechanical power
by the electrical power input (in %). However, most of the times, motor systems are only assembled at output divided
by
thethe electrical
end-user site,power
most input
of the(in
times%). impossible
However, most of the times,
to physically test motor
them. systems are only
On-site tests assembled
are sometimes
at the end-user
possible but aresite,
nevermost of the times
as precise impossible
as tests carried out to physically test them.
in laboratories On-site tests
in a controlled are sometimes
environment and
possible but are never
repeatable conditions. as precise as tests carried out in laboratories in a controlled environment and
repeatable conditions.
Inventions 2020, 5, 20 6 of 15

Inventions 2020, 5, x FOR PEER REVIEW 6 of 15

For this reason, a model for the determination of the losses of a motor system or a driven equipment
For this
is specified in reason, a model
IEC 61800-9, for athe
called determination model
semi-analytical of the (SAM).
losses ofThis
a motor system oronly
IEC standard a driven
covers
equipment is specified in IEC 61800-9, called a semi-analytical model (SAM). This IEC
electrical/electromechanical components (i.e., motor, VSD, motor starter), disregarding the mechanical standard only
covers electrical/electromechanical
components (i.e., mechanical transmission components
and load(i.e.,machine)
motor, VSD, motor
that are dealtstarter),
with bydisregarding the
the International
mechanical components
Organization (i.e., mechanical
for Standardization (ISO). transmission and load machine) that are dealt with by the
International Organization
IEC 61800-9-1 specifies afor Standardization
generic approach for (ISO).
determining the energy efficiency of an EPR, that can
IEC 61800-9-1 specifies a generic approach
be used to develop energy efficiency determination for determining
procedures the for energy efficiency of an
other non-electrical EPR, that
components.
Ascan be the
such, used to develop
extended product energy efficiency
approach (EPA,determination
Figure 5) specified procedures for other
in standard non-electrical
IEC 61800-9 can only
components. As such, the extended product approach (EPA, Figure 5) specified
be used to determine the losses of the electrical/electromechanical components of the motor system. in standard IEC
61800-9 can only be used to determine the losses of the electrical/electromechanical
The losses of the mechanical components need to be obtained from other sources such as the related components of
thestandards
ISO motor system. The losses
or product of the mechanical components need to be obtained from other sources
manufacturers.
such as the related ISO standards or product manufacturers.

Figure 5. The Extended Product Approach.

Figure 5. The Extended Product Approach.
The method can be used to determine the energy efficiency of the motor system for a particular
application, taking into account the time spent at the different operating points (speed-torque).
The method can be used to determine the energy efficiency of the motor system for a particular
Toapplication,
calculate the EEI, the following inputs need to be known:
taking into account the time spent at the different operating points (speed-torque). To
• calculate the EEI, the
Characteristics following
of the inputs
application need
load, to be known:
namely, the torque or power as a function of shaft rotational
• speed,
Characteristics
and the working time or fraction of time ofthe
of the application load, namely, each torque or power
operating pointas a function
(duty of shaft
cycle), including
rotational
standby mode. speed, and the working time or fraction of time of each operating point (duty cycle),
including standby mode.
• Power losses of components (Motor, CDM, end-use equipment, auxiliaries) at the operating points
• Power losses of components (Motor, CDM, end-use equipment, auxiliaries) at the operating
required by the application. Power losses are used instead of efficiency because they take into
points required by the application. Power losses are used instead of efficiency because they take
account particular conditions such as standby consumption (no-load condition, in which the
into account particular conditions such as standby consumption (no-load condition, in which the
efficiency is zero).
efficiency is zero).
Withthis
With thisinformation
informationand andusing
using the
the methodology
methodology specified
specified in in the
thestandard,
standard,thetheuser
userwill
willbebeable
able
to estimate power losses (PL) of the motor system and EPR at standardized operating points (OP)oror
to estimate power losses (PL) of the motor system and EPR at standardized operating points (OP)
theactual
the actualload
loadpoints
pointsofofa agiven
givenapplication,
application,asaswell
wellasastotocalculate
calculatethetheEnergy
EnergyEfficiency
EfficiencyIndex
Index(EEI)
(EEI)of
of the EPR for the given
the EPR for the given application.application.
Figure66illustrates
Figure illustratesthe the procedure
procedure considering
considering aa typical
typicalload loadprofile
profileofofpumps
pumpsusedusedininheating,
heating,
ventilation and air conditioning (HVAC) systems. The EEI allows
ventilation and air conditioning (HVAC) systems. The EEI allows the user to compare thethe user to compare theefficiency
efficiencyof
of different
different combinations
combinations of components
of components for for a given
a given application.
application. Furthermore,
Furthermore, thethe
EEIEEI will
will allow
allow forfor
the
the setting of energy efficiency labels and MEPS for EPRs as is the case for pumps in the US.
setting of energy efficiency labels and MEPS for EPRs as is the case for pumps in the US.
 Inventions
Inventions 2020,5,5,x 20
2020, FOR PEER REVIEW 7 of
7 of 1515

Figure 6. Example of application of the Extended Product Approach in typical load profiles of pumps
Figure 6. Example of application of the Extended Product Approach in typical load profiles of pumps
used in heating, ventilation and air conditioning (HVAC) systems.
used in heating, ventilation and air conditioning (HVAC) systems.

Beginning January 27, 2020, clean water pumps sold in the USA must have a Pump Energy
Beginning January 27, 2020, clean water pumps sold in the USA must have a Pump Energy Index
Index (PEI) rating of not more than 1.00 as outlined in the Energy Conservation Standards for Pumps
(PEI) rating of not more than 1.00 as outlined in the Energy Conservation Standards for Pumps
established by the USA [14]. The PEI must be displayed on the pump rating plate. The same approach
established by the USA [14]. The PEI must be displayed on the pump rating plate. The same approach
is being undertaken to establish similar regulations for the minimum efficiency of other motor products,
is being undertaken to establish similar regulations for the minimum efficiency of other motor
namely fans [15]. For the measurement of pump energy consumption and the calculation of PEI,
products, namely fans [15]. For the measurement of pump energy consumption and the calculation
a methodology was defined in cooperation with pump manufacturers and the Hydraulic Institute (HI).
of PEI, a methodology was defined in cooperation with pump manufacturers and the Hydraulic
Building on this methodology, the HI has gone one step further and developed an energy efficiency
Institute (HI). Building on this methodology, the HI has gone one step further and developed an
labelling program (HI Energy Rating Program) [16].
energy efficiency labelling program (HI Energy Rating Program) [16].
The label, as shown in Figure 7, also provides an Energy Rating (ER), which can be used to
The label, as shown in Figure 7, also provides an Energy Rating (ER), which can be used to
quantify energy savings potential. Multiplying the ER, in percentage, by the motor rated power (kW)
quantify energy savings potential. Multiplying the ER, in percentage, by the motor rated power (kW)
results in power savings compared to the baseline.
results in power savings compared to the baseline.
Inventions 2020, 5, 20 8 of 15
Inventions 2020, 5, x FOR PEER REVIEW 8 of 15

Figure 7. Example of USA Hydraulic Institute Energy Rating label for pumps.
Figure 7. Example of USA Hydraulic Institute Energy Rating label for pumps.
3.2. System Standards and New Motor Technologies
3.2. System Standards and New Motor Technologies
Growing awareness of the importance of energy-efficiency of motor systems has led to the market
introduction ofawareness
Growing of the importance
motors exceeding IE4 and IE5 of energy-efficiency
efficiency levels, using oftechnologies
motor systems suchhas led to the
as permanent
market introduction of motors exceeding IE4 and IE5 efficiency
magnet synchronous motors (PMSM), synchronous reluctance motors (SynRM), and copper levels, using technologies such as
rotor
permanent magnet synchronous motors (PMSM), synchronous reluctance
induction motors. SynRMs and PMSMs require the use of an electronic controller (VSD) to operate motors (SynRM), and
copper rotor induction
and, therefore, motors.ofSynRMs
are not capable competing andwith
PMSMs require the(DOL)
direct-on-line use ofsquirrel-cage
an electronicinduction
controllermotors
(VSD)
to operate and, therefore, are not
(SCIMs) in constant speed applications [17]. capable of competing with direct-on-line (DOL) squirrel-cage
induction motors
However, (SCIMs) in constant
in applications speedvariation
where speed applications [17].
is necessary, PMSMs and SynRMs can present
However, in applications where speed variation is necessary,
themselves as a viable alternative to induction motors, rivaling in reliability PMSMs and andexcelling
SynRMs in can present
efficiency.
themselves as a viable alternative to induction motors, rivaling in reliability
These motors operate at synchronous speed, eliminating almost entirely the losses in the rotor and are, and excelling in
efficiency. These motors
therefore, capable operate
of achieving at synchronous
very high efficiency speed,
levels,eliminating almost
even exceeding entirely the losses in the
IE5.
rotorBecause
and are,of therefore, capable of achieving very high efficiency levels, even
their improved characteristics, these technologies allow for a significant exceedingreduction
IE5. of
Because of their improved characteristics, these technologies allow for a
the motor size and weight, when compared to induction motors of similar efficiency. Additionally, significant reduction of
the
thesemotor
new size
motorandtechnologies
weight, when cancompared to induction
be engineered to presentmotors of similar
improved efficiency.
operating Additionally,
characteristics in
these new motor technologies
part-load operating regions. can be engineered to present improved operating characteristics in
part-load operating regions.
The development of standards that accommodate variable speed and torque operation presents
The development
itself as an opportunity for of standards
end-users thattoaccommodate
achieve both variable
improved speed and torque
performance andoperation presents
lower electricity
itself as an opportunity for end-users to achieve both improved performance and
consumption. Because of the large savings potential, there is a need to include these motor technologies lower electricity
consumption. Because which,
into future regulations of the until
largenow,
savings
have potential,
been limited there is a needmotors.
to induction to include these motor
Advanced motor
technologies into future regulations which, until now,
technologies are produced around the world, by a variety of manufacturers. have been limited to induction motors.
Advanced motor technologies are produced around the world, by a variety of manufacturers.
4. Experimental Power Drive System (PDS) Performance Comparison Using Different
Motor
5. Technologies
Experimental Power Drive System (PDS) Performance Comparison Using Different Motor
Technologies
To understand how the standards described above can be used to compare the energy and
economic performance
To understand of motors
how of different
the standards energy efficiency
described above canclasses andtousing
be used different
compare thetechnologies,
energy and
four different
economic 7.5-kW, three-phase
performance of motorsmotors were tested
of different using
energy the sameclasses
efficiency variable-speed
and using drive (VSD).
different
The losses of the
technologies, fourdifferent power
different drivethree-phase
7.5-kW, systems were determined
motors for theusing
were tested eight the
standardized load points.
same variable-speed
The
drivemethod
(VSD).described
The losses in the standard
of the is then
different useddrive
power to estimate
systemsandwere
compare the energy
determined for use
the of the
eight
tested motor systems for two different pumping applications with different load profiles.
standardized load points. The method described in the standard is then used to estimate and compare
the energy use of the tested motor systems for two different pumping applications with different load
4.1. Tested Motors and Test Setup
profiles.
In Table 1, the main characteristics of the tested motors, are presented. All the motors were tested
5.1.
usingTested Motors
the same andefficiency
high Test SetupVSD (Danfoss VLT Automation Drive FC 302), and the same control
strategy (torque/vector
In Table 1, the maincontrol).
characteristics of the tested motors, are presented. All the motors were tested
using the same high efficiency VSD (Danfoss VLT Automation Drive FC 302), and the same control
strategy (torque/vector control).
Inventions 2020, 5, 20 9 of 15

Table 1. Main characteristics of the tested 7.5-kW, 400-V, 50-Hz motors.

Inventions 2020, 5, x Motor

FOR PEER REVIEW
Class Type IN (A) f N (Hz) Poles ωN (rpm) 9 of 15

IE3 SCIM IE3 Al SCIM 13.9 50 4 1465

Table 1. Main characteristics of the tested 7.5-kW, 400-V, 50-Hz motors.
IE4 SCIM IE4 Cu SCIM 14.3 50 4 1475
Motor Class Type IN (A) fN (Hz) Poles ωN (rpm)
IE3 SCIM IE5 PMSM
IE3 IE5Al SCIM
PMSM 12.7
13.9 150
50 2 4 3000 1465
IE4 SCIM IE5 SynRM
IE4 IE5Cu SCIM
SynRM 17.6
14.3 5050 4 4 1500 1475
IE5 PMSM IE5 PMSM 12.7 150 2 3000
IE5 SynRM IE5 SynRM 17.6 50 4 1500
The VSD “Automatic Energy Optimization” option was enabled for all tested motors. In this
mode, theThe VSD continuously monitors the load of the motor and adjusts the output voltage accordingly
VSD “Automatic Energy Optimization” option was enabled for all tested motors. In this
to maximize the
mode, the VSD motor efficiency.monitors
continuously For low the
loadload
levels, the motor
of the VSD output voltage
and adjusts the isoutput
reduced until the
voltage
motoraccordingly
current is minimized. Enabling this option, the motor benefits from increased efficiency,
to maximize the motor efficiency. For low load levels, the VSD output voltage is reduced reduced
heating,
untiland
thequieter
motor operation.
current is minimized. Enabling this option, the motor benefits from increased
efficiency,
The reduced
test setup heating, andin
is represented quieter
Figure operation.
8. The reference line-to-line voltage at the VSD input was
The test setup is represented in
set to 390 V. The electrical measurements were Figure 8. The reference
made with aline-to-line
precision voltage
power at the VSD(YOKOGAWA
analyzer input was
set to 390 V. The electrical measurements were made with a precision power analyzer
WT1030M) at both input and output sides of VSD, which allowed direct determination of the motor, (YOKOGAWA
VSD,WT1030M) at both input and output sides of VSD, which allowed direct determination of the motor,
and PDS losses and efficiency for all load points.
VSD, and PDS losses and efficiency for all load points.

Figure 8. Simplified diagram of the setup used to perform the experimental tests.
Figure 8. Simplified diagram of the setup used to perform the experimental tests.

The losses of the PDS, PL,PDS , are determined by subtracting the measured output mechanical
The losses of the PDS, PL,PDS, are determined by subtracting the measured output mechanical
power, Pout ,Pto
power, the measured input electrical power, Pin(Equation
out, to the measured input electrical power, Pin
(Equation
1):(1)):
PL,PDS=Pin-Pout (1)
PL,PDS = Pin − Pout (1)

5.2. Experimental
4.2. Experimental Results
Results
According
According to Section
to Section 7.7.3.5
7.7.3.5 ofofthethestandard
standard IECIEC 61800-9-2,
61800-9-2,loss lossdetermination
determination of the
of PDS can be
the PDS can be
made using the input-output method, which was the applied procedure. The power losses the
made using the input-output method, which was the applied procedure. The power losses and and the
efficiency of the PDS was measured at the eight standardized load points defined in the same
efficiency of the PDS was measured at the eight standardized load points defined in the same standard.
standard. Taking the graph represented in Figure 2 (right) as reference, the required order of the
Taking the graph represented in Figure 2 (right) as reference, the required order of the measurements is
measurements is from right-top (point 1) to left-down (point 8), meaning (% of rated speed, % of
from rated
right-top (point
torque): 100,1)100);
to left-down (point
(50, 100); (0, 100); 8), meaning
(100, 50); (50,(%50);of(0,rated speed,
50); (50, 25); %
(0,of rated torque): 100, 100);
25).
(50, 100); (0, 100);
First, the (100,
PDS was50);run
(50,at50);
motor(0,rated
50); (50,
speed25); (0,torque
and 25). (point 1) until the motor reached a stable
First, the PDS was
temperature-rise run atasmotor
(defined rated speed
the external motor and torque (point
temperature measured1) until the at
directly motor reached a
the motor
stablehousing/frame
temperature-risesurface (defined
minus the as ambient
the external motor temperature
air temperature), meaning that measured directlyvariation
the temperature at the motor
was less than
housing/frame 2 K per
surface hour. the
minus Dueambient
to the shorter time constant, meaning
air temperature), it was assumed
that thethattemperature
the VSD hadvariation
also
achieved thermal stability at that time. When thermal stability is achieved,
was less than 2 K per hour. Due to the shorter time constant, it was assumed that the VSD had the supply voltage, input
current, input
also achieved power,
thermal input power
stability at thatfactor,
time.shaft
Whentorque, and shaft
thermal speedis
stability were measured
achieved, theand recorded
supply voltage,
with a precision power analyzer. All other operating points were measured in successive order
input current, input power, input power factor, shaft torque, and shaft speed were measured and
Inventions 2020, 5, 20 10 of 15

recorded with a precision power analyzer. All other operating points were measured in successive
order immediately. The operating points at 50% (point 2) and at 20% (point 3) of rated speed were
measured with unchanged torque settings. The motor torque was then reduced to 50% of its rated
value, and measurements were taken at 100% (point 4), 50% (point 5) and 20% (point 6) of rated speed.
Finally, motor torque was reduced to 25% of its rated value for the measurement at 50% (point 7) and
Inventions 2020, 5, x FOR PEER REVIEW 10 of 15
20% (point 8) of rated speed.
Asimmediately.
electric motors exhibit an
The operating uneven
points at 50%current
(point 2)distribution and3)therefore
and at 20% (point uneven
of rated speed heating in their
were measured
with unchanged torque settings. The motor torque was then reduced to 50%
coils when the supply frequency is zero or very close to zero, the standard allows for the PDS of its rated value, andlosses to
measurements were taken at 100% (point 4), 50% (point 5) and 20% (point 6) of rated
be measured at a speed corresponding to up to 12 Hz stator frequency instead of zero speed (300 r/min speed. Finally,
motor torque was reduced to 25% of its rated value for the measurement at 50% (point 7) and 20%
for the SCIMs and SynRM and 200 and 600 rpm for the PMSM). These losses were used without further
(point 8) of rated speed.
extrapolation Asas the losses
electric motorsatexhibit
the load pointscurrent
an uneven (3), (6), and (8), as
distribution andshown in Table
therefore uneven2.heating in their
coils when the supply frequency is zero or very close to zero, the standard allows for the PDS losses
to be measured at aTable Considered motor
speed2.corresponding speed
to up to forstator
12 Hz the eight load points.
frequency instead of zero speed (300
r/min for the SCIMs and SynRM and 200 and 600 rpm for the PMSM). These losses were used without
Motor Technology Load Points (1), (4) Load Points (2), (5), (7) Load Points (3), (6), (8)
further extrapolation as the losses at the load points (3), (6), and (8), as shown in Table 2.
100% 50% 20%
IE3 SCIM Table 2.1465
Considered
rpm motor speed for the
733eight
rpmload points. 300 rpm
Motor 100%
Load Points 50%
Load Points Load Points20%
IE4Technology
SCIM (1),rpm
(4) (2),738
(5), rpm
(7) (3), (6), (8)rpm
1475 300
100% 50% 20%
IE3 SCIM 100% 50% 7% & 20%
IE5 PMSM 1465 rpm 733 rpm 300 rpm
3000 rpm
100%
1500
50%
rpm 200
20%
& 600 rpm
IE4 SCIM
1475
100%rpm 738 rpm
50% 300 rpm 20%
IE5 SynRM 100% 50%rpm 7% &30020%rpm
IE5 PMSM 1500 rpm 750
3000 rpm 1500 rpm 200 & 600 rpm
100% 50% 20%
IE5 SynRM
In Figure 9, the measured losses1500
of the
rpmPDS as a percentage
750 rpmof the output rated
300power
rpm are presented
for the four In Figure
tested 9, the measured losses of the PDS as a percentage of the output rated power are
motors.
presented for the four tested motors.

Figure 9. PDS
Figure losses
9. PDS asas
losses a percentage of the
a percentage of theoutput
output rated
rated power
power (7.5 kW).
(7.5 kW).

In termsIn of
terms of efficiency,
efficiency, the the
bestbest systemisisthat
system that with
with PMSM
PMSMIE5IE5
forfor
all the
all eight operating
the eight points, points,
operating
as expected.
as expected.
5.3. Estimation of the PDS Lifetime Energy Performance for Particular Applications
4.3. Estimation of the PDS Lifetime Energy Performance for Particular Applications
As discussed in Section 3.2., knowing the values of the PDS losses in the eight operating points
Asdefined
discussed in Section
in standard 3.2., knowing
IEC61800-9 the to
allows users values of the
evaluate the performance
PDS losses (both
in the eight and
energy- operating
points defined in standard
economic-wise) IEC61800-9
of any application forallows users operating
which typical to evaluate theare
points performance
known. In this(both
paper,energy-
two and
Inventions 2020, 5, 20 11 of 15

economic-wise) of any application for which typical operating points are known. In this paper,
two pumping applications with different load profiles shown in Table 3 are examined. The first load
profile (LP1) corresponds to a typical HVAC application, while the second (LP2) is the typical load
profile for a clean water pumping application, defined on the basis of the results of the European
Ecodesign Directive Pump study [18,19].

Table 3. Load profiles for typical pumping applications.

Load Profile 1 (LP1)

% of Rated Flow Rate 25% 50% 75% 100%
% Time Share 45% 35% 15% 5%
Load Profile 2 (LP2)
% of Rated Flow Rate 25% 50% 75% 100%
% Time Share 0% 25% 50% 25%

The losses at these percent flow rate points are known from the tests for load points (100, 100)
and (50, 25), and need to be estimated, for points (75, 50) and (25, 12.5). The estimation is done by
interpolation using the method defined in standard IEC61800-9-2. Hence, the power losses for the
operating point (75, 50) can be calculated using Equation (2):

PL(100,50) − PL(50,50)
PL(75,50) = PL(50,50) + × 25 (2)
50
In a similar manner, the power losses for the operating point (25, 12.5) can be calculated using
Equation (3):

PL(50, 25) − PL(0,25)

PL(25,12.5) = PL(0,25) + × 25
50
 P L(50, 50) − PL(0,50) PL(50, 25) − PL(0,25) 
 PL(0,50) + × 25 PL(0,25) + × 25 
 
50 50 (3)
− −
 

 25 25 


×12.5

Combining the test results with the estimated values gives the PDS losses for all operating points
(Table 4).

Table 4. PDS losses for four different motor technologies and four different load points.

Motor Technology
PDS Load Points
SCIM IE3 SCIM IE4 SynRM IE5 PMSM IE5
(25; 12.5) 4.64% 4.43% 3.39% 4.43%
(50; 25) 3.81% 3.61% 2.40% 3.61%
(75; 50) 5.83% 5.38% 4.85% 5.38%
(100; 100) 13.83% 11.24% 10.90% 11.24%

Knowing the losses at these load points and the time spent at each load point for the defined
application (see Table 3) allows users to estimate the energy use of their application and compare
the energy performance of different technical solutions as well as their economics. For the economic
evaluation of the four different technologies, the assumptions presented in Table 5 were made.
Inventions 2020, 5, 20 12 of 15
Inventions 2020, 5, x FOR PEER REVIEW 12 of 15
Inventions 2020, 5, x FOR PEER REVIEW 12 of 15

Table Table 5. Assumptions

5. Assumptions for thefor the calculation
calculation of the life-cycle
of the life-cycle cost of cost of the
the four four analyzed
analyzed motor
motor technologies.
Table 5. Assumptions for the calculation of the life-cycle cost of the four analyzed motor
technologies.
technologies. Maintenance 1
Motor Technology Motor Price VSD Price MaintenanceLifetime
1
Motor Technology Motor Price VSD Price (4000 h/year)Maintenance 1 Lifetime
Motor Technology Motor (4000 h/year)
SCIM IE3 600 €Price VSD
1200 € Price €
450 (4000 h/year)15 years Lifetime
SCIM IE3 600 € 1200 € 450 € 15 years
SCIMSCIM
SCIM IE3 IE4
IE4 600€€€
720
720
€ €
12001200
1200 €
450 € 450 €
450 €
15 years 15 years
SynRM IE5 720 € 1200 € 450 € 15 years 15 years
SCIM IE4
SynRM IE5 720 €€
720 1200 €€
1200 450 €€
450 15 years
PMSM IE5 1200 € 1200 € 450 € 15 years 15 years
SynRM IE5IE5 720 €€ 1200 €€ 450 €€ 15 years
years
1 For PMSM
the maintenance
1200
cost, three repairs
1200 450 15
PMSM
1For the IE5 1200are
€ considered for 1200
a motor
€ operating 8000 h/year
450 € with a linear decrease
15 years
maintenance
with operating hours. cost, three repairs are considered for a motor operating 8000 h/year with a linear
1For the maintenance cost, three repairs are considered for a motor operating 8000 h/year with a linear
decrease with operating hours.
decrease with operating hours.
A comparison
A of the
comparison of the estimated
estimated total
total cost
cost of
of ownership
ownership (TCO)
(TCO) for
for the
the two
two different
different load
load profiles
profiles
A comparison
considered is
considered of
is shown
shown inthe estimated
in Figures 10and
Figure 10 total cost
andFigure of ownership
11, considering (TCO)
the motor
11, considering for the
is running
the motor two different
for 4000
is running load
forh/year. profiles
4000 h/year.
considered is shown in Figure 10 and Figure 11, considering the motor is running for 4000 h/year.

Figure 10. Disaggregated TCO for the different motor technologies and LP1.
Figure 10.
Figure Disaggregated TCO
10. Disaggregated TCO for
for the
the different
different motor
motor technologies
technologies and
and LP1.
LP1.

Figure 11.
Figure Disaggregated TCO
11. Disaggregated TCO for
for the
the different
different motor
motor technologies
technologies and
and LP2.
LP2.
Figure 11. Disaggregated TCO for the different motor technologies and LP2.
Figures 12 and 13 show the results of the calculation of simple payback considering a different
Figures
number 12 and 13
of operating show
hours the
per results
year. of the calculation
As would be expectedof simple improves
payback payback considering a different
with growing number
number of operating hours per year. As would be expected payback improves with growing number
Inventions 2020, 5, 20 13 of 15

Figures 12 and 13 show the results of the calculation of simple payback considering a different
Inventions 2020, 5, x FOR PEER REVIEW 13 of 15
number of operating
Inventions 2020, hours
5, x FOR PEER per year. As would be expected payback improves with growing number
REVIEW 13 of 15
of
of yearly
yearly operating
operating hours. Likewise, the
hours. Likewise, the investment
investment gets
gets more
more favorable
favorable faster
faster in load profile
in load profile 22 where
where
of yearly
the energy operating
consumptionhours.
is Likewise,
more the investment
important due to gets
the more
motor favorable
working morefaster
timeinatload profile
higher load 2 points.
where
the energy consumption is more important due to the motor working more time at higher load points.
the energy consumption is more important due to the motor working more time at higher load points.

Figure 12. Payback time for SCIM IE4, SynRM IE5, and PMSM IE5, in relation to SCIM IE3, for LP1.
Figure
Figure 12. Payback time
12. Payback time for
for SCIM
SCIM IE4,
IE4, SynRM
SynRM IE5,
IE5, and
and PMSM
PMSM IE5,
IE5, in
in relation
relation to
to SCIM
SCIM IE3,
IE3, for
for LP1.
LP1.

Figure
Figure 13. Payback time
13. Payback time for
for SCIM
SCIM IE4,
IE4, SynRM
SynRM IE5,
IE5, and
and PMSM
PMSM IE5,
IE5, in
in relation
relation to
to SCIM
SCIM IE3,
IE3, for
for LP2.
LP2.
Figure 13. Payback time for SCIM IE4, SynRM IE5, and PMSM IE5, in relation to SCIM IE3, for LP2.
The results show that the load profile of the application has a great influence on its energy
The results show that the load profile of the application has a great influence on its energy
The results
consumption, as show
wouldthat the load profile
be expected. of the
Therefore, theapplication
influence ofhas theaload
great influence
profile on the oninvestment
its energy
consumption, as would be expected. Therefore, the influence of the load profile on the investment
consumption,
economics as would
is also large. beIn expected. Therefore,
applications where thethe motor
influence of the load
is running at lowprofile
loadsonfor
thea investment
significant
economics is also large. In applications where the motor is running at low loads for a significant
economics
amount is also
of time, as large. In applications
is the case whereuses
for typical HVAC the (LP
motor is running
1), the at lowor
loss reduction loads for a gain
efficiency significant
when
amount of time, as is the case for typical HVAC uses (LP 1), the loss reduction or efficiency gain when
amount of
moving time,
from theasSCIM
is the IE3
casetofor typical
SCIM IE4HVAC
or PMSMuses IE5
(LPmay1), the loss
not bereduction
enough toorjustify
efficiency gain when
the additional
moving from the SCIM IE3 to SCIM IE4 or PMSM IE5 may not be enough to justify the additional
moving
initial from the SCIM
investment. On theIE3 to SCIM
other hand, IE4 or PMSM
for load IE5
profiles in may
which notthebePDS
enough to justify
is running the additional
at higher loads for
initial investment. On the other hand, for load profiles in which the PDS is running at higher loads
initial periods
larger investment. On the
of time, such other hand,
as LP2, thefor load profiles
investment in which
in higher the PDS
efficiency is running at
technologies higher more
becomes loads
for larger periods of time, such as LP2, the investment in higher efficiency technologies becomes more
for larger periods
attractive. of time, of
If the number such as LP2, the
operating hoursinvestment
is longerin higher
than 6000efficiency technologies
h/year, the investment becomes more
in the tested
attractive. If the number of operating hours is longer than 6000 h/year, the investment in the tested
attractive. If the number of operating hours is longer than 6000 h/year, the investment in the tested
IE4-IE5 motor technologies leads to a payback time lower than three years for LP2. Because of their
IE4-IE5 motor technologies leads to a payback time lower than three years for LP2. Because of their
efficiency and comparatively lower costs in relation of other IE4 and IE5 technologies, synchronous
efficiency and comparatively lower costs in relation of other IE4 and IE5 technologies, synchronous
reluctance motors lead to the most cost-effective solutions in variable load pumping applications.
reluctance motors lead to the most cost-effective solutions in variable load pumping applications.
Inventions 2020, 5, 20 14 of 15

IE4-IE5 motor technologies leads to a payback time lower than three years for LP2. Because of their
efficiency and comparatively lower costs in relation of other IE4 and IE5 technologies, synchronous
reluctance motors lead to the most cost-effective solutions in variable load pumping applications.
As can be seen by these results, the standardized methodology described in the IEC 61800-9
standard series can be an important instrument for end-users to compare the different solutions available
on the motor systems component market. Such a tool was, until now, unavailable. The publication of
losses data for the eight standardized load points in manufacturers catalogues will hopefully become
widespread and a valuable aid in energy efficient equipment selection, triggering energy savings and
corresponding CO2eq emissions reduction in a cost-effective manner.

5. Conclusions
As can be seen by the results presented, the same motor, CDM or PDS can have different energy
efficiency performance depending on the characteristics of the application they are used in. It is
very important that end-users have the information they need to estimate this performance, namely
the load profile, and choose the combination of components in a PDS that yields the largest energy
savings while being economically attractive. The new IEC 61800-9 standard series sets the basis for a
standardized comparison between different PDS technologies for the particular end-use application it
is intended for, providing the necessary information to find the best PDS component combination in
terms of energy efficiency and cost-effectiveness. This is made possible by the definition of standardized
points where the partial-load efficiency of VSDs and PDS needs to be determined and published by
manufacturers. The standard establishes a straightforward, transparent, internationally harmonized
method to determine the PDS energy efficiency, which can help users in product selection and
manufacturers improve their products. Ultimately, the new IEC 61800-9 standard series can be an
important tool to boost the energy efficiency of electric motor driven systems worldwide.

Author Contributions: Conceptualization, J.F. and A.T.d.A.; Formal analysis, J.F.; Investigation, F.J.T.E.F.
and A.M.S.; Methodology, J.F. and A.T.d.A.; Supervision, A.T.d.A.; Validation, F.J.T.E.F.; Visualization, J.F.;
Writing—original draft, J.F.; Writing—review & editing, J.F., F.J.T.E.F. and A.T.d.A. All authors have read and
agreed to the published version of the manuscript.
Funding: This research was funded by Fundação para a Ciência e a Tecnologia (FCT) and COMPETE 2020
program, grant UIDB/00048/2020.
Acknowledgments: The author thanks the International Electrotechnical Commission (IEC) for permission
to reproduce Information from its International Standards. All such extracts are copyright of IEC, Geneva,
Switzerland. All rights reserved. Further information on the IEC is available from www.iec.ch. IEC has no
responsibility for the placement and context in which the extracts and contents are reproduced by the author, nor
is IEC in any way responsible for the other content or accuracy therein.
Conflicts of Interest: The authors declare no conflict of interest.

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