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B Y A N Í B A L T . D E A L M E I D A ,
FERNANDO J.T.E. FERREIRA,
& J O Ã O A . C . F O N G
IEEE INDUSTRY APPLICATIONS MAGAZINE JAN j FEB 2011 WWW.IEEE.ORG/IAS
1077-2618/11/$26.00©2011 IEEE
motor market transformation, a new international standard, of PMSM technology in that respect, which, in general,
International Electrotechnical Committee (IEC) 60034-30 are significant.
[3], was approved in November 2008 to globally harmo-
nize motor energy efficiency classes in general purpose, sin- New Motor Efficiency Classification Standard
gle-speed, line-fed, three-phase, squirrel-cage IMs. In this IEC 60034-30 [3] is intended to globally harmonize motor
standard [3], three efficiency classes are proposed, standard energy efficiency classes in general purpose, line-fed (direct
efficiency (IE1) [the designation of the energy efficiency on-line connection) IMs used in stationary applications,
class consists of IE (short for International Energy Efficiency defined according to IEC 60034-1 [7]. The classification
Class), directly followed by a numeral representing the clas- standard also applies to IMs rated for two or more voltages
sification], high efficiency (IE2), equivalent to EPAct, and and frequencies. IMs in the 0.75–375-kW power range
premium efficiency (IE3), equivalent to National Electrical make up the vast majority of installed motor population
Manufacturers Association (NEMA) premium. In addition, and are covered by this standard. For the application of IEC
in the last proposal of the IEC 60034-31 technical specifica- 60034-30 standard, motor efficiency and losses shall be
tion standard, a super-premium efficiency (IE4) is also pro- tested in accordance with IEC 60034-2-1 [8] using a low
posed, intended to be informative, since no sufficient uncertainty method, such as the “summation of losses” test
market and technological information is available to allow procedure with stray load losses (SLLs) determined from
its standardization and more experience with such products residual loss—a procedure similar to IEEE 112-B [11]. The
is required. All the IE1, IE2, IE3, and IE4 efficiency levels are rated efficiency and the efficiency class shall be durably marked
defined for the 0.75–375-kW power range, equivalent to the on the rating plate. In a motor with dual-frequency rating,
1–500-hp range. both 50- and 60-Hz efficiencies shall be marked for each rated
Regarding the IE4 class, some European manufacturers voltage/frequency combination. Motors with full-load effi-
see no technical feasibility to reach the first IE4 proposed ciency equal to or exceeding an efficiency class boundary
levels with IM technology with the same IEC frame sizes are classified in that efficiency class. As stated previously,
(defined in [5]) as IE1/IE2-class IMs. However, very high- IE1, IE2, and IE3 classes are normative [3], [4], [10].
efficiency motors with permanent magnet (PM) rotor Motors covered by this standard may be used in VSD
technology are being introduced in the market, which allow applications (for further information, see Application Guide
not only reaching but overtaking the proposed IE4 levels. IEC 60034-17); however, in these cases, the marked effi-
The IE4 class under consideration can be applied both ciency of the motor shall not be assumed to apply because of
to line-fed motors and inverter plus motor units. For low- the increased losses from the harmonic voltage content of
power levels (up to 7.5 kW), it is clear that moving away the VSD power supply. Motors specifically built for opera-
from IM technology and considering emergent technolo- tion in explosive atmospheres (according to IEC Standards
gies such as PM synchronous motors (PMSMs), either 60079-0 and 61241-1) are also covered by this classification
88
86 90
84 Four Poles
82 88
50 Hz, IE1
80 50 Hz, IE2
86
50 Hz, IE3
78 Four Poles
50 Hz, IE4
76 60 Hz, IE1 84
74 60 Hz, IE2
60 Hz, IE3 82
72 60 Hz, IE4
70 80
0.1 1 10 100 0.1 1 10 100
Motor-Rated Power (kW) Motor-Rated Power (kW)
(a) (b)
1
IEC 60034-30 and 31 efficiency levels and NEMA and EPAct minimum efficiency requirements for 60- and 50-Hz,
four-pole IMs [10].
frequency on motor efficiency [4], resulting for four-pole All efficiency curves are given in mathematical formula
IMs, in the levels presented in Figure 1 for four-pole IMs. in smooth form to allow for various regional and national
This approach will enable manufacturers to build motors distinctions for frame dimensions and motor sizes.
for dual rating (50/60 Hz). The approved IEC 60034-30 efficiency classification
The levels of the IE4 efficiency class are envisioned standard will harmonize the current different requirements
IEEE INDUSTRY APPLICATIONS MAGAZINE JAN j FEB 2011 WWW.IEEE.ORG/IAS
to be incorporated into a future edition of IEC 60034-31 for IM efficiency levels around the world, hopefully ending
technical specification standard. The goal is to reduce the difficulties that the manufacturers encounter when pro-
the losses of IE4 by about 15% relative to IE3. Tech- ducing motors for a global market. Additionally, custom-
nologies other than IMs will be required to meet IE4 ers will benefit by having access to a more transparent and
levels [3]. easier to understand information.
98
100
IE3-Class Efficiency Levels 96
98 Above-IE3-Class Efficiency
Levels (Case 1) 94
Motor Efficiency (%)
90
92
88
90
86
88
84
86 Four Poles, 50 Hz
82
0.1 1 10 100
84 Motor-Rated Power (kW)
Four Poles, 50 Hz
IE3-Class Efficiency Levels
82
0.1 1 10 100 Above-IE3-Class Efficiency Levels (Case 2)
Motor-Rated Power (kW) IE4-Class Efficiency Levels
6 7
2 2
Full-load efficiency levels after rotor I R losses elimination in Full-load efficiency levels after rotor I R losses elimination
four-pole, 50-Hz, IE3-class IMs, denoted as above-IE3-class and stator I2R losses reduction in 50-Hz, four-pole, IE3-class
16
efficiency levels (Case 1). IMs, denoted as above-IE3-class efficiency levels (Case 2).
Industrial Motors: Line-Start PMSMs with Auxiliary Rotor and reach synchronization. In this case, there are additional
Cage” section do not exist, and therefore, the rotor losses are losses associated with the VSD itself and in the motor be-
extremely low. However, the motors with such rotors have cause of the PWM voltage-related harmonic losses.
to be EC by inverters (or VSDs) to be able to properly start When integrated in the system, although the energy
savings potential associated with speed regulation, VSDs
have a negative impact on the full-load efficiency motor
system because of their internal losses and to the additional
100 high-frequency losses in the motor. In Figures 9 and 10,
the VSD efficiency typical levels and variation of efficiency
98 with load are presented.
96
100
94
Motor Efficiency (%)
95
92
90
86 75
94
Motor Efficiency (%)
98
92
96
90
VSD Efficiency (%)
94 88
86
92
84
90 Four Poles, 50 Hz
Typical Full-Load Efficiency 82
0.1 1 10 100
88 for Standard VSDs
Motor-Rated Power (kW)
Full-Load Efficiency for
High-Efficiency 11
Four VSDs
Poles, 50 Hz
86 Full-load efficiency levels for motor-VSD units, considering
0.1 1 10 100 rotor I2R loss elimination and stator I2R and core losses
VSD-Rated Power (kW) reduction in four-pole, 50-Hz, IE3-class IMs, and the
9 VSD efficiency, denoted as above-IE3-class efficiency
levels (Case 4).
17
Typical full-load efficiency levels for VSDs.
Considering the impact of the inverter output PWM vol- VSD output PWM waveforms in the motor efficiency is
tages on the motor efficiency as well as the inverter effi- not considered.
ciency, the overall efficiency is given by (3), where gvsd is
the VSD efficiency (in percent), gorig is the original effi- Comparison of Standard
ciency of the motor (in percent), gnew is the motor-VSD and Commercial Efficiencies
unit efficiency (in percent), and Dgorig is the motor effi- Some manufacturers sell integrated PMSMþVSD solutions,
ciency decrease (in percentage points). which achieve full-load efficiency values significantly higher
than IE3 class. In Figure 12, the full-load efficiency of
commercial PMSMþVSD units from two different manu-
gnew ¼ 102 gvsd gorig Dgorig : ð3Þ
facturers, as well as the estimated maximum achievable
full-load efficiency levels for PMSMþVSD units, is shown.
Using (3), Case 4 is analyzed in terms of efficiency It can be seen that, for the low-power range, efficiency
reduction due to the efficiency of the VSD, and the results improvements are still possible.
are presented in Figure 11. In this case, the impact of the
Materials Usage
IE2-class IMs incorporate more active materials than PMSMs,
as can be seen in Table 1 and Figure 13. According to two
98 PMSM manufacturers, PMSMþVSD units and IE2-class
Four Poles, 50 Hz IMþVSD units have an equivalent manufacturing cost.
96 However, IE3-class IMþVSD units incorporate more materi-
als and have a higher cost. Moreover, considering that copper
94 is not used in the rotor, IE3-class premium IMs incorporate
much more material than IE2-class IMs.
92
Therefore, in variable-speed applications, when com-
pared with IE3-class IMþVSD units, PMSMþVSD units
use less active materials. Even considering the additional
90
Motor Efficiency (%)
Conclusions
82 Growing environmental concerns and high energy costs
emphasize the importance of considering the life-cycle costs
80 of nonstandard technologies. PM motors prove to be signifi-
cantly more efficient than IMs, particularly in the low-power
78 range. Moreover, they have higher power factor and cooler
operating temperature. Former disadvantages, such as the
76
0.1 1 10 100
Motor-Rated Power (kW) 1.1 kW/Four Poles
8
IE3-Class Efficiency Levels
7 IE1 IM_al
IE4-Class Efficiency Levels
IE2 IM_cu
Estimated Maximum Efficiency for 6 PMSM + VSD
EC-PMSM (Case 4)
IE1 IM + VSD
Brand A, Four-Pole, EC-PMSM 5
Line-Start PM
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