IEC Motor Efficiency Classes from IE1 to IE5

Martin Doppelbauer Univ.-Prof. Dr.-Ing. Convenor IEC TC2 WG31 Karlsruhe Institute of Technology (KIT) Institute of Electrical Engineering (ETI) Hybrid Electrical Vehicles (HEV)

IEC TC2 Working groups overview

IEC TC2 WG28 Performance as determined by tests 36 Members, Convenor Axel Möhle IEC 60034-2-1, 1st ed 2007-09 Determination of motor efficiencies IEC 60034-2-2, 1st ed 2010-03 Losses of large machines IEC 60034-2-3, under preparation Losses of converter fed machines IEC 60034-4, 3rd ed 2008-05 Synchronous machine quantities IEC 60034-19, 1st ed 1995-07 Specific tests for d.c. machines IEC 60034-28, 1st ed 2007-03 Quantities of equivalent circuit diagrams IEC 60034-29, 1st ed 2008-03 Indirect testing to determine temperature

IEC TC2 WG31 Efficiency Classes 32 Members, Convenor Martin Doppelbauer IEC 60034-30, 1st ed 2008-10 Ranking of motor efficiencies IEC 60034-31, 1st ed 2010-04 Energy-efficient motors - Application guide

Martin Doppelbauer

Current Status

Still applicable IEC 60034-2-1, 1st ed 2007-09 Determination of motor efficiencies IEC 60034-30, 1st ed 2008-10 Ranking of motor efficiencies

Under preparation IEC 60034-2-1, 2nd ed Determination of motor efficiencies ► CDV is expected for early 2013 (currently in french translation) IEC 60034-2-3, 1st ed Determination of extra harmonic losses ► DTS is expected for early 2013 (currently in french translation) IEC 60034-25, 3rd ed 2014? Performance of converter fed motors ► 2/1689/CD (2nd CD – closing date 2013-03-01) IEC 60034-30-1 Classification of motor efficiencies (grid) ► 2/1679/CDV (closing date 2013-01-04) IEC 60034-30-2 Classification of motor efficiencies (variable f) ► NWIP is expected for summer 2013 IEC 52800-x, 1st ed Efficiency of frequency converters, power ► Prepared by TC22x drive systems and complete drive systems ► currently CDV on CENELEC level (CLC 52800-x: Energy efficiency and Eco-design requirements for Power drive systems, motor starters, Power electronics and their driven applications)

Martin Doppelbauer

New motors covered in IEC 60034-30-x

Three-phase AC-induction

IEC 60034-30 1st ed 2008-10

Grid fed (fixed speed)

Three-phase AC-induction Wound-rotor AC-induction Single-phase AC-induction Sinusoidal-field reluctance Line-start permanent-magnet ...

IEC 60034-30-1

Martin Doppelbauer

Converter fed (variable speed)

Permanent-magnet synchronous Wound-rotor synchronous ...

IEC 60034-30-2

New motors covered in IEC 60034-30-1

IEC 60034-30-1 Motor technology and their energy-efficiency potential

Martin Doppelbauer

Enhancement of output power range

0,75 1,1 1,5 2,2 3 4

5,5 7,5 11 15

18,5 22 30 37 45 55 75 90

110 132 160 200

0,75 1,1 1,5 2,2 3,7 5,5 7,5 11 15

18,5 22 30 37 45 55 75 90

110

50 Hz 60 Hz 0,12 0,18 0,20 0,25 0,37 0,40 0,55

0,12 0,18 0,25 0,37 0,55

Curves from 1st edition have been extrapolated downwards

No change of the well established values

250 315 355 400 450

...1000

150 ...

1000

Fixed values from 1st edition remain constant, but are being prolonged up to 500 kW

Martin Doppelbauer

New normative IE4 class

• IE4 now defined according to output power • 50 Hz IE4 values are losely oriented on the

informative annex of IEC 60034-31 • 60 Hz IE4 values are a stepped curve

defined by NEMA

4-pole

Martin Doppelbauer

Further changes

• 8-pole motors have been added;

• High voltage motors still not covered;

• Definition of type of operation improved to close loop holes: „... capable of continuous operation at their rated power with a temperature rise within the specified insulation temperature class“;

• Definition of ambient temperature improved to close loop holes: „... marked with any ambient temperature within the range of– 20 °C up to + 60 °C“;

• Definition of rated altitude improved to close loop holes: „marked with an altitude up to 4 000 m above sea level.“

• Definition of brake motors improved to close loop holes: „... excluded are brake motors, when the brake is an integral part of the inner motor construction and can neither be removed nor supplied by a separate power source during testing of the motor efficiency“ (Note: Brake coil losses are disregarded in efficiency determination)

Martin Doppelbauer

IEC 60034-30

Motors excluded from IEC 60034-30-x

Variable Speed Non-Sinusoidal Voltage

DC-motors Switched reluctance motors EC-motors (brushless-DC) ...

Have to be tested as complete drive

system

Very high speed Very low speed

Can not be rated into the

IE1, IE2, IE3, IE4 classification scheme

Motors with completely integrated brake

Sliding rotor motors ...

Brake motors are only excluded when the

brake can not be dismantled or separately fed.

Martin Doppelbauer

IEC 60034-30

Motors excluded from IEC 60034-30-x

Extended temperature < -20 °C and > +60°C

Smoke extraction motors above 400°C Cold storage warehouse motors Oven supply motors ...

Motors completely integrated into a machine

Motor can not be tested independently

of the load

Testing and classification as complete

power drive system

Motors with integrated frequency converters

Piggy back converter On-coil electronics ...

Martin Doppelbauer

Next level of technology: IE5

IE 5 ?

“The levels of the IE5 efficiency class are envisaged to be incorporated into the next edition of this standard. It is the goal to reduce the losses of IE5 by some 20% relative to IE4. Motor technologies for IE5 are currently not well developed and not commercially available. Further energy-efficiency optimizations will have to focus on improved system efficiency throughout the entire operating load cycle including all system-losses (converter, filter, cables, motor etc.) – see EN 52800.”

© ThinGap

Martin Doppelbauer

IEC 60034-2-3: Some results of extra harmonic losses

Martin Doppelbauer

In this example, extra harmonic losses are small (max 4% of losses on sinusoidal power supply) and independent of load

IEC 60034-2-3: Some results of extra harmonic losses

Martin Doppelbauer

In this example, extra harmonic losses are bigger (max 14% of losses on sinusoidal power supply) and dependent of load

Martin Doppelbauer Univ.-Prof. Dr.-Ing. Convenor IEC TC2 WG31 Karlsruhe Institute of Technology (KIT) Institute of Electrical Engineering (ETI) Hybrid Electrical Vehicles (HEV)