How the efficiency of induction motor is measured?

S. Corino E. Romero L.F. Mantilla

Department of Electrical Engineering and Energy

E.T.S.I.I. y T. Universidad de Cantabria
Avda de Los Castros, 39005 Santander (Spain)

phone:+34 942 201381, fax:+34 942 201381, e-mail: [email protected]

Abstract
The efficiency is of paramount importance nowadays due There are different efficiency definitions that
to increasing electrical energy demand, increasing awareness of describe the relationship between a motor’s rating and
environmental problems as greenhouse effects and increasing efficiency test results:
fossil fuel prices.
- Tested. This refers to the efficiency measured
This paper tries to show the different results between the by testing that specific motor.
standards for efficiency evaluation and the necessity of - Nominal or Average Expected. Nominal
harmonization worldwide. Then, it is going to be explained the values are the average values obtained after
different standards for measurement of efficiency, and the main testing a sample population of the motor
differences between the standards (IEEE 112, IEC 60034-2 and model.
JEC-37). - Nameplate. This refers to the efficiency
measured by a specific standard.
To complete this study, it is going to be described the steps - Minimum. These values are intended to
in order to estimate efficiency on the jobsite and expressed the
different efficiency labels motors.
represent the lowest point in the bell curve of
motor efficiency distribution.
Keywords: energy efficiency, induction motor, standard. - Apparent Efficiency. This is the product of a
Code: 352-mantilla motor’s efficiency and power factor.

1. Introduction
Pout
The efficiency is of paramount importance nowadays Pin
because electrical motors are major consumers of 10%
5%
electricity in the modern industrial society; they consume 25% 20%
approximately 69% of electricity in the industrial and 40%
approximately 36% in the tertiary sectors of the European Paddit
Union [1]. Three-phase, low voltage squirrel cage Pfr,w
PFe
induction motors are the most commonly used electric Protor
motors in industry. Pstator

Efficiency data by manufacturers are measured or Figure 2.1 – Typical energy flow of standard motors [2].
calculated according to certain standards. The main
differences between these standards are discussed in this B. Motor Losses
paper. Energy losses are the determining factor in motor
efficiency. These losses can be divided in five classes:
There are a lot of examples of agreements, incentives
and initiatives worldwide in order to promote increasing Percent
the efficiency. In Europe, there is an initiative called Name
of
Description
Fixed or How to
SEEEM (Standards for Energy Efficiency of Electric Total Variable reduce
Motors Systems). SEEEM aims to stimulate and Losses
accelerate the process of harmonization in order to save Improved
energy and reduce greenhouse gas emissions. permeability
Energy steel,
Core required to lengthening
2. Losses and Efficiency 15-15% Fixed
Losses magnetize core, using
core. thinner
A. Definition of energy efficiency laminations in
Efficiency is the ratio of mechanical energy output the core.
divided by the electrical energy input. Windage 5-15% Losses due Fixed Lower friction
 and to bearing bearings, United Institute of Electric and IEEE 112
Friction friction and improve fan States Electronic Engineers
air design and air United American National C50.20 (based on
resistance, flow. States Standards Institute IEEE 112)
which is United National Electrical MG1-12.58.1
primarily States Manufacturers Association (based on IEEE
caused by 112)
the cooling Canada Canadian Standards C-390
fan. Association
Increasing the International International IEC 34-2
volume of Electrotechnical
Heating due copper wire in Commission
to current the stator,
flow through Japan Japanese Electrotechnical JEC-37
Stator Committee
25-40% through the Variable improved
Losses Great British Standards BS-269
resistance stator slot
of the stator designs, and Britain
winding. by using Table 3.1 – Motor Testing Standards [2].
thinner
insulation. A. IEEE Standard 112
Increasing the The Institute of Electric and Electronic Engineers
Heating due
size of rotor (IEEE) Standard 112, Standard Test Procedures for
to I2R
conductive
Rotor losses in the Polyphase Induction Motors and Generators, is the
15-25% Variable bars and end
Losses rotor standard used for testing induction motors in the United
rings to
conductive States.
reduce
bars.
resistance.
Leakage This standard includes a total of ten test methods for
fluxes efficiency. Next, we’ll quote the most important:
induced by Various - Method A: Simple Input-Output. This method
Additional
load design and is used to load the motor while the torque and
Load 10-20% Variable
currents and manufacturing speed are measured to calculate load. This is
Losses
various details. limited to small motors.
other minor
- Method B: Input-Output with loss segregation
losses.
(or separation). This method uses a
Table 2.1 – Classes of Motor Energy Losses [2].
dynamometer. This is an instrument that
The main difference between the standards emerges maintains a constant torque resistance,
from the way in which the additional load losses, is allowing motor load to be calculated. This test
treated. The IEC 34.2 standard assumes a standard value can be used in motors from 1 to 250hp.
for the additional load losses at rated load of 0.5% of the - Method C: Back to back machine test with
input power. The new proposed IEC 61972 standard separation of losses. One machine is operated
gives two possibilities for the assessment of the as a motor while the other becomes a
additional losses. The first one is a determination by generator, returning power back to the
means of the measured output power, as in the IEEE 112- electrical grid. The efficiency is measured by
B; the second one gives a fixed amount to every machine dividing the total losses by two.
of the same rated power. The Japanese JEC standard 37 - Method F: Equivalent circuit calculation. This
completely neglects the additional load losses. is usually the least accurate way to calculated
motor efficiency because such a large portion
of losses are not directly measured.
Paddit = ( Pin − Pout ) − ( PFe + Pstator + Protor + Pfr ,w ) (1)
The IEEE 112-B standard estimates the efficiency by
3. Motor Efficiency Testing Standards the direct method:
Pout
There are several different motor testing standards η DM = (2)
which prescribe specific procedures, such as what test
Pin
equipment may be used, how long the motor is to run The electric input power is measured using a high-
prior to testing, how loads are to be applied, what data accuracy wattmeter and the output power is measured
are to be collected, and how various losses are to be using a speed sensor and a torque sensor. This is an
measured. accurate method, if the instrumentation has the desired
accuracy and the test procedure is followed rigorously.
The next table shows test standards for medium size
induction motors that are used in different parts of the B. IEC Standard 60034-2
world. The IEC’s test can be classified in three types:
 - Input-Output Measurement Power of one Methods Comparison
machine: This involves the measurement of
400
mechanical input or output power. 350
- Input-Output Measurement Power in back-to- 300
back machines: This eliminates the 250
EN-60034-2
IEEE 112B
measurement of mechanical input or output 200

W
IEC 61972
150
power. 100
IEEE 112E

- Measurement Real Losses of one machine: It is 50

applied in order to calculate the total or 0

particular losses. 0 2000 4000 6000 8000 10000 12000 14000 16000 18000
Shaft power

It is distinguished two ways of efficiency Figure 3.1 – University of Nottingham: Result of 1 of 5 motors
measurement: in the direct method, the input and output of 11kW [5].
power are measured directly, as the expression (2); and
the indirect method measures the losses, output power is Methods Comparison
equal losses plus input power (3).
3000
P
η IM = 1 − losses (3) 2500

Pin 2000
IEEE 112E
1500 IEC 61972

W
EN 60034-2
In the next paragraph, it is going to be explained the 1000

different methods that are included in this standard: 500

0
0 20000 40000 60000 80000 100000 120000 140000
- Method of Tared Motor. Shaft power
The machine is separated of the electrical grid
and it is disconnected of its driver motor. It is Figure 3.2 – University of Nottingham: Result of 1 of 5 motors
achieved the full load speed thanks to the tared of 75kW [5].
motor. The mechanical power that is
transmitted by from the tared motor to shaft, Methods Comparison

are the power losses of the machine. 3500

- Method with Power Factor zero. 3000
The machine operates unloaded, full load 2500
speed and power factor near zero. The 2000
IEEE 112-E
IEC 61972
excitation current is regulated in order to
W

1500
EN 60034-2
achieve the nominal current in the primary. 1000

- Method of deceleration. 500

Consist in the measurement of the time 0

0 20000 40000 60000 80000 100000 120000 140000 160000 180000
applying in its deceleration. This method lets Shaft power
the measurement the mechanical losses, core
losses and short-circuit losses. Figure 3.3 – University of Nottingham: Result of 1 of 5 motors
- Method back-to-back. of 110kW [5].
This method can be applied when two equal
machines are available. One of them operates The following table shows the results of 13 motors
as a motor and the other one, as a generator. tested in Natural Resources Canada:
- Method calorimetric.
This method is being studied. Efficiency
Efficiency
Difference
with in
Size with Eh-star
C. Comparative cases between Standards indirect percentage
method
The comparative cases try to prove the disagreement method points
between different standard methods. (hp) (%) (%) (p.p.)
2 84.7 85.1 0.42
The following graphics are supported in a study of 5 88.7 88.7 0.00
University of Nottingham published by CEMEP 2005. 5 86.7 86.5 -0.21
Seven motors were tested with Standard IEEE 112- 10 89.7 89.6 -0.04
E, Standard IEEE 112-B, EN 60034-2, and IEC 61972. 10 91.0 91.1 0.09
The tests were done different sizes of motors such as 20 93.2 93.4 0.17
11kW, 75kW and 110kW. 50 92.8 93.1 0.28
The results can be seen in the figures 3.1, 3.2 and 3.3: 55kW 92.5 93.1 0.54
75 93.0 93.2 0.16
90kW 93.7 94.4 0.71
 125 94.8 95.1 0.29 ±20% difference between actual slip and nameplate slip
150 95.9 96.3 0.34 when the ambient temperature is 25ºC. Thus, depending
200 95.9 95.9 0.03 upon manufacturing and test variations, the nameplate
Table 3.2 – Results of 13 test, published at the Motors Summit could properly be stamped 1760±20% of 40rpm:
2007 in Zurich [5]. Maximum slip = 48;rpm = 1752
Minimum slip = 32; rpm = 1768
The eh-star method consist an asymmetric feeding of
a three-phase induction motor. The unbalanced condition The accuracy of the slip method is, however, limited
is obtained by operating the motor in star connection and by multiple factors, and is generally not recommended
then switching from normal three phase to single phase for determining motor loads in the field.
operation where the disconnected phase is connected
back to the supply through a resistor. Eh-star is an
economical method with good accuracy where stray load 5. Identification of Efficiency on the Market
losses are calculated mathematically.
A classification scheme was introduced that
categorized motors into three efficiency classes
4. Estimation Efficiency on the Jobsite depending on motor type, number of poles, and most
importantly, size (see figure 5.1). There are three labels
Three steps are used to estimate efficiency and load. in order to classify the efficiency: Eff1, Eff2 and Eff3.
First, use input power, line current or slip measurements
to identify the load imposed on the motor. Second, obtain This classification is possible thanks to voluntary
a motor part-load efficiency value. Finally, obtain a agreement between CEMEP (the European Committee of
modified load using the power measurement at the motor Manufacturers of Electrical Machines and Power
terminals and the part-load efficiency value. Electronics) and the European Commission.
A. Input Power Measurements
You can then quantify the motor’s part-load by
comparing the measured input power under load to the
power required when the motor operates at rated
capacity. The relationship is shown in equation (4)
Pi
Load = × 100% (4)
Pir
With Load the output power as a % of rated power,
Pi, the measured three phase power in kW; and Pir, the
input power al full rated load in kW.

B. Line Current Measurements

The current load estimation method is recommended
when only amperage measurements are available.
Figure 5.1 – Energy efficiency classification scheme for a range
In the low load region, current measurements are no of two poles motors from different manufacturers [3].
longer a useful indicator of load.
Thus, root mean square current measurements should
always be corrected for voltage.

C. The Slip Method

The slip method is recommended when only motor
operating speed measurements are available.
The motor load can be estimated with slip Figure 5.2 – Efficiency labels [3].
measurements as shown in equation (5):
I V The motors included in this scheme are defined as
Load = × × 100% (5) totally enclosed fan ventilated (IP 54 or IP 55), three
I r Vr phase A.C. squirrel cage induction motors, 50 Hz, S1
With Load, as output power as a % of rated power, I duty class.
is the RMS current (mean of 3 phases); Ir the nameplate
rated current; V, the RMS voltage, mean line to line of 3 kW Eff3 Eff2 Eff1
phases; and Vr, the nameplate rated voltage. 1.1 <76.2 ≥76.2 ≥83.8
1.5 <78.5 ≥78.5 ≥85.0
As an example [8], suppose a 460V motor’s “true” 2.2 <81.0 ≥81.0 ≥86.4
full-load rpm is 1760. The slip is 40rpm. NEMA allows 3 <82.6 ≥82.6 ≥87.4
 4 <84.2 ≥84.2 ≥88.3 Phase, Cage Induction Motors”, Vol. 38, No. 2, pp.609-613,
5.5 <85.7 ≥85.7 ≥89.2 March/April 2002.
7.5 <87.0 ≥87.0 ≥90.1
[7] P. Van Roy and R. Belmans, “Assessment of Efficiency of
11 <88.4 ≥88.4 ≥91.0 Low Voltage Three Phase Motors”, pp. 95-96, Berlin 2003.
15 <89.4 ≥89.4 ≥91.8
18.5 <90.0 ≥90.0 ≥92.2 [8] “Understanding Energy Efficiency Motors”, Electrical
22 <90.5 ≥90.5 ≥92.6 Apparatus Service Association (EASA), pp. 15-20.
30 <91.4 ≥91.4 ≥93.2 http://www.easa.com/
37 <92.0 ≥92.0 ≥93.6
[9] G. A. McCoy and J. G. Douglas, “Energy Management for
45 <92.5 ≥92.5 ≥93.9
Motor-Driven Systems”, The U.S. Department of Energy Office
55 <93.0 ≥93.0 ≥94.2 of Industrial Technologies, Washington, March 2000, pp 5.1-
75 <93.6 ≥93.6 ≥94.7 5.8.
90 <93.9 ≥93.9 ≥95.0
Table 5.1 – Efficiency of four poles motors [4].

6. Conclusions
The analysis presented shows that it can be obtained
different results depending on the standard used. These
differences have been proved thanks to graphical
examples. It is necessary to eliminate the disagreements
between the methods of the different standards because
they make for serious consequences in order to certificate
and to declare efficiency values.

This fact can be got through International

Harmonization Initiative promoting by SEEEM. This
process of harmonization deals the energy saving and the
reduction greenhouse emissions.

To sum up, this study has tried to shed light of

knowledge of different standards for efficiency
measurement and to emphasize the necessity of
harmonization worldwide.

7. References
[1] H. Falkner, “Promoting High Efficiency Motors in Europe.
The role of the copper Industry”, ETSU. European Copper
Institute, pp. 13, November 2000.

[2] T. Litman, “Efficient Electric Motor Systems Handbook”,

The Fairmont Press, INC., Oklahoma (1995), pp. 21-37.

[3] S. Fassbinder, “Saving energy with high-efficiency motors”,

Leonardo Energy, pp. 6-7, September 2007.
http://www.leonardo-energy.org

[4] EURODEEM New Features Added, December 2007.

http://sunbird.jrc.it/energyefficiency/eurodeem/index.htm

[5] C.U.Brunner, “International Standards for Electric Motors”,

Standards for Energy Efficiency of Electric Motor Systems
(SEEEM), pp. 6-10, November 2007. http://www.seeem.org

[6] A. T. de Almeida, F. J. T. E. Ferreira, et al, “Comparative

Analysis of IEEE 112-B and IEC 34-2 Efficiency Testing
Standards Using Stray Load Losses in Low-Voltage Three-