Current Developments in IEC

standards for Energy Efficiency

of Electric Motors

Martin Doppelbauer
Univ.-Prof. Dr.-Ing.
Karlsruhe Institute of Technology (KIT)
Institute of Electrical Engineering (ETI)
Professorship of Hybrid Electric Vehicles (HEV)

International

IEC

CENELEC COPANT
Europe

Public

Regional

international

...

Panamericans

BSI

ANSI

CSA

JIS

England

USA

Canada

Japan

...

National

DKE
Germany

ZVEI

VIK

IEE

NEMA

IEEE

UL

Germany

Germany

England

USA

USA

USA

Martin Doppelbauer, Univ.-Prof. Dr.-Ing.

...

Private

VDE
Germany

2, 4, 6-pole
3-phase ASM
No special design
(Ex, Brake, ...)
S1-continuous duty
0,75 ... 375 kW

June 16, 2011

IE2 mandatory

January 1, 2015

IE3 mandatory
or IE2 + Drive
(from 7,5 ... 375 kW)

January 1, 2017
3

Martin Doppelbauer, Univ.-Prof. Dr.-Ing.

IE3 mandatory
or IE2 + Drive

Preparatory Studies:

Lot 28: Pumps for private and public waste water and for fluids with high solid
content

Lot 29: Pumps for private and public swimming pools, ponds, fountains and
aquariums, as well as clean water pumps larger than those regulated under Lot 11

Lot 30: Electric Motors outside of the scope of Regulation 640/2009

Lot 31: Compressors, including small compressors and their possible drives

Martin Doppelbauer, Univ.-Prof. Dr.-Ing.

Products in Drive Systems outside the scope of EU 640/2009

The study is commenced by Prof. Almeida (University of Coimbra, Portugal)

and Hugh Falkner (Faithful&Gould, UK)

Other types of motors, for example

Permanent-Magnet Motors from 120W up to 1000 kW
Motors for variable speed from 120W up to 1000 kW
Motor starters and variable speed drives from 200 W up to 1000 kW

Product categories
Small motors 120 W up to 750 W
Medium motors 0,75 kW up to 375 kW
Large motors 375 kW up to 1000 kW
Low voltage motors up to 1000 V
Medium voltage motors up to 6600 kVA
Focus on drive systems: Power supply,
Controller, Motor, Coupling, Load, Process

Conclusion of the study in early 2014

Task 1: Product Definition, Standards and Legislation

Task 2: Economic and Market Analysis
Task 3: Consumer Behavior and Local Infrastructure
Task 4: Technical analysis existing products
Task 5: Definition of Base Case

Martin Doppelbauer, Univ.-Prof. Dr.-Ing.

Mandate M/470 EN
June 23, 2010

Standardisation in the field of

electric motors

Elaborate reliable, accurate and reproducible measurement methods; Redefinition and reduction
of test tolerances; provide values for measurement uncertainties
All types of motors (for example single phase induction motors, permanent magnet synchronouzs
and reluctance motors) including motors designed for converter operation
Starting from between 200 to 500W, as appropriate, up to 500 kW, at minimum
Determination of part load 50% and 75% efficiencies
Definition of energy efficiency classes for any new technologies, for example PM-motors
Definition of efficiency levels of the IE4 and a future IE5 class (attainable only for non-induction
motors)
Definition of test measurement methods and efficiency levels for motors designed for converter
operation
Define a template for test report
Standards developed within 48 months

IEC TC2, WG28 Convenor Dr. Axel Mhle / Siemens

IEC 60034-2-1, 2nd ed, Determination of motor efficiencies

IEC 60034-2-3, 1st ed, Determination of extra harmonic losses of converter fed AC induction motors

IEC TC2, WG31 Convenor Prof. Dr. Martin Doppelbauer / KIT

IEC 60034-30-1, 1st ed, Classification of motor efficiencies IE1-4 (on line connected)
IEC 60034-30-2, 1st ed, Classification of motor efficiencies IE1-4 (variable speed motors)
Martin Doppelbauer, Univ.-Prof. Dr.-Ing.

Mandate M/476 EN
November 30, 2010

Standardisation in the field of

variable speed drives and/or Power Drive Systems

Develop procedures and methods for measuring the energy efficiency, efficiency classes,
load and speed profiles and associated characteristics of variable speed drives and/or of
Power Drive Systems (PDS) equipped with variable speed drives, as appropriate
To provide values for measurement uncertainties
To define a standard template for a test report indicating the information to be declared by
the manufacturers
Standards developed within 36 months

CENELEC TC22X, WG06 Convenor Dr. Benno Weis / Siemens

EN 50598-1

EN 50598-2

EN 50598-3

Energy efficiency standard with extended product approach (EPA)

and semi analytic model (SAM)
Energy efficiency for power drive systems, motor starters, power electronics
and their driven applications
Environmental aspects and product declaration for power drive systems
and Motor starters

IEC SC22G, AG15 Convenor Martial Patra / Schneider Electric

IEC xyz

publication of EN 50598-2 at IEC under the Unified Acceptance

Procedure (UAP)

Martin Doppelbauer, Univ.-Prof. Dr.-Ing.

Determination of efficiency and losses of grid-connected motors

April 2008

Meeting in Helsinki, Finnland

Collection of items to be considered in the next edition

Oct 2008

Meeting in Birr, Switzerland

2/1538/DC Proposal for revision of IEC 60034-2-1

June 2009

Meeting in St. Petersburg, Russia

2/1555A/INF (Result of 2/1538/DC)

Sept 2010

Meeting in Passau, Germany

2/1628/INF (Result of Round Robin Test

June 2011

Meeting in Zrich, Switzerland

2/1648/CD (2011-12-09)

May 2012

Meeting in Kyoto, Japan

2/1687/CDV (2013-01-04)

May 2013

Meeting in Istanbul, Turkey

2/xxxx/FDIS (End of 2013)

2014

Publication of IS

Martin Doppelbauer, Univ.-Prof. Dr.-Ing.

Determination of efficiency and losses of grid-connected motors

Structure of the document has been simplified:

Chapter 3: Terms and definitions
Chapter 4: Symbols and abbreviated terms
Chapter 5: Basic requirements
Chapter 6: Test methods induction machines
Chapter 7: Test methods synchronous machines
Chapter 8: Test methods DC machines

Flow charts for a precise definition of individual steps

References for preferred and other testing methods
Some requirements on instrumentation have been raised slightly

Martin Doppelbauer, Univ.-Prof. Dr.-Ing.

Measurement of additional harmonic losses of motors fed by converters

The decision to split IEC 60034-2 in three parts was already taken in 2005, work started in 2008
April 2008
Oct 2008
June 2009

Meeting in Helsinki, Finnland

Meeting in Birr, Switzerland
Meeting in St. Petersburg, Russia
2/1570/CD (2009-08-28)

Sept 2010

Meeting in Passau, Germany

2/1626/CDV (2011-04-08) -> rejected!

June 2011
May 2012

Meeting in Zrich, Switzerland

Meeting in Kyoto, Japan
2/1643A/RVC (2012-07-13) -> create TS instead of IS
2/1696/DTS (2013-01-25) -> accepted

End of 2013

Publication of TS

10

Martin Doppelbauer, Univ.-Prof. Dr.-Ing.

Measurement of additional harmonic losses of motors fed by converters

11

define test methods for determining the additional harmonic motor losses of converter-fed
induction motors
the motor is part of a Power Drives System (PDS), see EN 50598-2
Aim: to create a comparability between motors regarding their additional harmonic losses
Measurements are performed under standardized conditions with the motor supplied by a
reference converter (uncontrolled 2 / 4 kHz PWM converter without over-modulation)
The measured losses are for reference only and do not represent the actual losses in any
given application

Martin Doppelbauer, Univ.-Prof. Dr.-Ing.

Energy Efficiency Classification of line operated AC motors (Part 1)

Energy Efficiency Classification of variable speed motors (Part 2)
April 2011

Frankfurt, Germany
2/1632/CD (2011-05-06)

Sept 2011

Alexandria, VA, USA

2/1652/CD (2011-12-23)

June 2012

Kyoto, Japan
It was decided to split the document 60034-30 in two parts
2/1679/CDV of Part 1 (2012-09-21)

May 2013

Istanbul, Turkey
2/1709/NWIP of Part 2 (2013-06-14)
2/xxxx/FDIS of Part 1 (End of 2013)

2014

Publication of IS of Part 1

12

Martin Doppelbauer, Univ.-Prof. Dr.-Ing.

Energy efficiency classification (IE)

IEC 60034-30
1st ed 2008-10
Three-phase
AC-induction

IEC 60034-30-1
Grid fed
(fixed speed)

100% Last
100% Drehzahl

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

2, 4, 6, 8-pole
0,12 ... 1000 kW

IEC 60034-30-2
Converter fed
(variable speed)

25, 50, 75, 100% Last

25, 50, 75, 100% Drehzahl

Permanent-magnet synchronous
Wound-rotor synchronous
...

100 ... 10000/min

0,12 ... 1000 kW

13

Martin Doppelbauer, Univ.-Prof. Dr.-Ing.

Variable Speed
Non-Sinusoidal Voltage
DC Motoren
Switched reluctance motors
EC-Motoren (blockkommutiert)
...

Motors with integrated

frequency converters

Motors completely
integrated into a machine

Piggy back converter

On-oil electronics
...

Can not be tested

independent of
load

Test and classification as Power Drive System (PDS)

EN 50598-2

14

Martin Doppelbauer, Univ.-Prof. Dr.-Ing.

Efficiency classes for converters (IE) and power drive systems (IES)

Individual IE-classifications for all types of components (Motor, Converter, Gearbox?, ...)
IES-classification for the power drive system (PDS = Motor + Converter + Auxiliaries)
Extended Product approach (EPA) = Extended Product + Duty Profile + Control Curve
Calculation of reference figures on the basis of measurements (Semi Analytic Model = SAM)

relative
losses in %

20

PDS
Motor CDM fed
Motor sinusoidal
fed

12

CDM
4

10

15

Martin Doppelbauer, Univ.-Prof. Dr.-Ing.

20

50

80

100 rpm in %

Increased efficiency = decreased related power losses

Efficiency classes for converters (IE) and power drive systems (IES)
Line fed
motors
Efficiency

Converter
fed
motors
Efficiency

Converters (CDM)
losses related to
rated power

Power Drive
systems (PDS)
losses related to
rated power

IE0 not used

IE0 u.c.

IE0 more than 25%

higher than
reference value

IES0 more than

20% higher than
reference value

IE1 can be
mostly
technically
achieved

IE1 u.c.

IE1 - reference
value 25%

IES1 - reference
value 20%

IE2 can be
achieved by
enhancement

IE2 u.c.

IE2 more than 25%

lower than reference
value

IES2 more than

20% lower than
reference value

IE3 needs
significant
amount of
techniques

IE3 u.c.

IE3 u.c.

IES3 u.c.

IE4 will
require new
techniques

IE4 u.c.

IE4 u.c

IES4 u.c

IE5
experimental
new
technologies

IE5 u.c.

IE5 u.c

IES5 u.c

IE6 not used

IE6 u.c.

IE6 u.c

IES6 u.c

IE7 not used

IE7 u.c.

IE7 u.c.

IES7 u.c.

IE8 not used

IE8 u.c.

IE8 u.c.

IES8 u.c.

IE9 not used

IE9 u.c.

IE9 u.c.

IES9 u.c.

u.c. = under consideration

16

Martin Doppelbauer, Univ.-Prof. Dr.-Ing.

Current
IEC 60034-2-1 ed.1.0 (2007)
IEC 60034-30 ed.1.0 (2008)
IEC 60034-17 ed.4.0 (2006)
IEC 60034-25 ed.2.0 (2007)

Determination of motor efficiencies

Ranking of motor efficiencies
Performance of standard motors on
converter
Performance of special converter motors

Future
IEC 60034-2-1 ed.2.0 (2014)
IEC 60034-2-3 ed.1.0 (2013)
IEC 60034-30-1 ed.1.0 (2014)
IEC 60034-30-2 ed.1.0 (2016)?
IEC/EN 50598-2 ed.1.0 (2016)?
IEC 60034-25 ed.3.0 (2015/16)?

17

Martin Doppelbauer, Univ.-Prof. Dr.-Ing.

Determination of motor efficiencies

Determination of extra harmonic losses
Ranking of grid fed motor efficiencies
Ranking of variable speed motor efficiencies
Efficiency of frequency converters, power
drive systems and complete drive systems
Performance of converter fed motors

Martin Doppelbauer
Univ.-Prof. Dr.-Ing.
Karlsruhe Institute of Technology (KIT)
Institute of Electrical Engineering (ETI)
Professorship of Hybrid Electric Vehicles (HEV)