Energy Innovators Initiative

Technical
Fact Sheet

Premium-Efficiency Motors
Description The energy consumption of a motor is determined by three
factors. The relationship is as follows:
Electric motor systems
consume large amounts of Energy Consumption = (Operating Hours x Load) ÷ Motor Efficiency
electrical energy and can
provide an opportunity for As demonstrated in the equation above, a higher level of
significant energy savings. efficiency results in an overall reduced level of consumption.

Energy represents more Motor efficiency varies with load. The efficiency of motors
than 97 percent of total Figure 1 –
typically peaks at close to 75 percent of full load and is
motor operating costs over Premium-Efficiency Motor relatively flat down to a 50 percent load point (see Graph 1).
the motor’s lifetime. However,
Graph 1 – Motor Load Efficiencies
the purchase of a new motor often tends to be driven by
the price, not the electricity it will consume. Even a small 100 75 – 100 hp
Full-Load Efficiency (percent)

improvement in efficiency could result in significant energy 30 – 60 hp

80 15 – 25 hp
and cost savings. Investing a little more money upfront for 10 hp
1.5 – 5.0 hp
a more efficient motor is often paid back in energy savings. 60
0 – 1 hp
Improving energy efficiency reduces greenhouse gas 40
emissions that contribute to climate change.
20

Organizations should have a back-up plan in place to deal 0

0 20 40 60 80 100 120
with motor failures. When a motor fails is often the best
Full Load (percent)
opportunity to install a more efficient motor, rather than
repairing it.
Most motors are operated at 60 to 75 percent of their
Technical Specifications
rated capacity.
Motors turn electrical energy into mechanical energy. Motor
Oversized motors have a lower rate of efficiency when they
efficiency is the ratio of mechanical power output to electrical
are in operation. A motor that is operating at a 35 percent
power input. In other words, motor efficiency represents the
load is less efficient than a smaller motor that is matched
percent of input energy that is converted into useful work.
to the same load.
A motor’s nameplate rating is based on output horsepower
When motors operate near their rated load, the power factor
(hp), which is fixed for continuous operation at full load.
(PF) is high. For lightly loaded motors, the PF drops signifi-
The amount of input power needed to produce the rated
cantly (see Graph 2). In addition to increased electrical costs,
horsepower will vary from motor to motor, with more-efficient
a lower PF may reduce the building’s voltage, increase electrical
motors requiring less input wattage than less-efficient
distribution system losses and reduce the system’s capacity to
models to produce the same output.
deliver electrical energy.

Natural Resources Ressources naturelles

Canada Canada
Table 1 – NEMA Nominal Full-Load Efficiencies for Selected Induction Motors (600 Volts or Less)
Horsepower 5 7.5 10 15 20 25 30 40 50 75 100 125 150 200
Standard*** 87.3 87.4 88.5 89.4 89.2 90.1 90.7 92.0 92.3 92.6 93.1 94.1
ODP*
1200 RPM Energy Efficient 87.5 88.5 90.2 90.2 91.0 91.7 92.4 93.0 93.0 93.6 94.1 94.1 94.5 94.5
(6 Pole)**
Premium Efficiency 89.5 90.2 91.7 91.7 92.4 93.0 93.6 94.1 94.1 94.5 95.0 95.0 95.4 95.4

Standard 87.0 88.2 89.6 90.0 90.6 90.7 91.6 92.2 92.3 92.6 93.3 94.2
TEFC*
1800 RPM Energy Efficient 87.5 89.5 89.5 91.0 91.0 92.4 92.4 93.0 93.0 94.1 94.5 94.5 95.0 95.0
(4 Pole)**
Premium Efficiency 89.5 91.7 91.7 92.4 93.0 93.6 93.6 94.1 94.5 95.4 95.4 95.4 95.8 96.2

* Open drip-proof (ODP) and totally enclosed fan-cooled (TEFC) motors use different methods to remove heat from the windings.
ODP motors have an internally mounted fan that allows air to blow directly through the motor and has a cover that prevents drops of liquid from entering (suitable for
protected environments).
TEFC motors use an externally mounted fan that draws air over the case to provide cooling and are designed to prevent outside air from flowing into the frame (motors
can function outdoors and in dusty or contaminated environments).
** Motors are available at rated synchronous speeds that are determined by the number of poles for which the motor is wound and the frequency of the power supply.
The synchronous speed is calculated from this formula: Revolutions per minute (RPM) = (120 x Frequency) ÷ Number of Motor Winding Poles. For 60-hertz frequency, the
synchronous speeds are as follow: 2 poles = 3600 RPM, 4 poles = 1800 RPM, 6 poles = 1200 RPM.
*** The values are average full-load efficiency for standard motors and may be used as an estimate when the manufacturer cannot provide actual motor efficiency values.
(Source: U.S. Department of Energy)

Graph 2 – Motor Power Factors The Canadian Standards Association (CSA) developed
200 – 250 hp
a Canadian standard in 1993 and updated it in 1998.
100
150 hp CAN/CSA-C390 set the requirement for minimum
Power Factor (percent)

80 100 – 125 hp
40 – 75 hp efficiency for new motors made or sold in Canada at the
60 15 – 30 hp same value as the NEMA “energy-efficient” level.
5 – 10 hp
40
Nominal efficiency levels for both “energy-efficient” and
20 “premium-efficiency” motors for some selected types and
0 sizes are presented in Table 1. (The entire table is available
35 45 55 65 75 85 95 through NEMA).
Full-Load Amperage (percent)

Energy Information

While motor full- and part-load PF characteristics are To calculate the annual energy consumption and cost savings
important, they are not as significant as efficiency. When from replacing a motor with a higher-efficiency one, the
selecting a motor, current practice is to purchase for formula in Box 1 should be used.
efficiency and correct for PF.
The motor horsepower can be obtained from the nameplate,
When a motor is oversized and lightly loaded, the PF will be and the efficiencies for the existing and replacement motors
lower compared with a motor that is sized properly. A facility can be obtained from manufacturers or suppliers.
with many induction motors and a low PF may address this
The load factor in the equation must be determined by
issue by replacing motors with premium-efficiency motors
using an electrical measurement instrument when the motor
that are properly sized.
is running in its normal operating mode. The equation
In the motor marketplace, three terms are used to label shown in Box 2 is used for three-phase motors to determine
motors: “high-efficiency,” “energy-efficient” and “premium- the load factor.
efficiency.” Only the last two terms have definitions estab-
Most electrical measurement instruments can determine
lished by the National Electrical Manufacturers Association
power directly. If they cannot, by measuring the voltage,
(NEMA1). In 1989, NEMA first developed and adopted
current and PF, the equation in Box 3 may be used for
energy-efficient performance values in its MG-1 standard
three-phase motors to determine power. To determine the
(Motors & Generators-1), which was incorporated in Canada's
input power at full-rated load, the equation in Box 4 is used.
Energy Efficiency Regulations in 1997 for minimum efficiency
levels on certain 1-200 hp motors. In 2001, NEMA launched
the NEMA Premium™ Efficiency Electric Motors Program,
which covered many more motor types and sizes.

1 NEMA is a trade association that establishes standards to help in the selection and application of electric motors and other electrical equipment.
Table 2 – Comparison of Various-Sized Motors
Efficiency Type Data Horsepower
5 7.5 10 15 20 25 30 50
Efficiency at 75% Load 84.0 86.0 88.4 89.3 90.8 90.9 91.6 91.8
Standard
Efficiency Annual Consumption (kWh) 24 978 36 595 47 469 70 486 92 428 115 408 137 432 228 554
Annual Cost ($) 1,499 2,196 2,848 4,229 5,546 6,925 8,246 13,713

Efficiency at 75% Load 90.7 91.9 92.4 92.6 93.1 93.6 94.4 94.9
NEMA
Premium-Efficiency Annual Consumption (kWh) 23 133 34 246 45 414 67 974 90 145 112 079 133 355 221 088
Annual Cost ($) 1,388 2,055 2,725 4,078 5,409 6,725 8,001 13,265
Annual Savings (kWh) 1 845 2 349 2 055 2 512 2 283 3 329 4 077 7 466
Annual Savings ($) 111 141 123 151 137 200 245 448
List Price ($) 533 724 814 996 1,294 1,700 1,771 2,751
Purchase Price ($) 426 579 651 797 1,035 1,360 1,417 2,201
Payback (years) 3.9 4.1 5.3 5.3 7.6 6.8 5.8 4.9

Boxes 1 to 4 – Energy Information Caution: If energy-efficient motors are misapplied, they

may not achieve predicted energy savings and may actually
Demand savings (kW) = (hp x 0.746) x (LF) x (1/Eexist – 1/Ereplace)
Consumption savings (kWh) = (Demand savings) x (Operating hours) 1 result in diminished performance and reduced motor life.
Any motor selection must be properly engineered for its
Annual cost savings = (kWh savings x kWh rate)
intended application. For centrifugal fans and pumps, an
Where: increase in operating speed will increase the required power
hp = motor nameplate horsepower
0.746 = conversion from hp to kW
by the third power of the speed ratio. For example, by
LF = load factor as percent of full-rated load (e.g. 70 percent, 80 percent) increasing the speed by only 25 RPM – from 1740 to
Eexist and Ereplace = efficiency of existing and replacement motors (in percent)
1765 RPM – a 4.4 percent increase in the load will be
placed upon a motor, i.e. (1765 ÷ 1740)3 = (1.014)3 = 1.044.
On average, energy-efficient motors have higher full-load
speeds than standard motors. When replacing a standard-
LF = (PI ÷ PIR)
2 efficiency motor, a high-efficiency motor with lower or equal
Where: full-load speed must be selected to avoid the energy increase
PI = measured three-phase input power (in kW)
PIR = input power at full-rated load (in kW) that may negate the predicted energy savings resulting from
a higher efficiency. To provide the correct flow, it may be
necessary to adjust fan sheaves or pump-impeller diameters.
MotorMaster+ (Version 4.0) software, developed by
PI = (V x I x PF x 1.732) ÷ 1000 Washington State University and funded by the U.S.
3 Department of Energy (DOE), is a popular and free tool
Where:
PI = power (in kW) to calculate the savings for premium-efficiency motors.
V = voltage, mean line-to-line of three phases
I = current (in A), mean of three phases
Through its comprehensive and regularly updated databases,
PF = power factor (in percent) it helps estimate the efficiency of existing motors and provides
performance and price list (in U.S. dollars) of premium-
efficiency motors.

PIR = (hp x 0.746) ÷ EFF Comparison

4
Where: The initial cost of a premium-efficiency motor will typically
PIR = input power at full-rated load (in kW)
hp = horsepower from nameplate be 15 to 30 percent more than an energy-efficient one.
EFF = efficiency at full-rated load
In addition to the energy savings, premium-efficiency and
energy-efficient motors offer other benefits. In general, they
are of a higher quality, are more reliable, last longer, have
longer warranties, run more quietly and cooly and produce
less waste heat than their less-efficient counterparts.
Premium-efficiency and energy-efficient motors may be The manufacturer’s data shows that the motor efficiency at
more suited for use with a variable speed drive than their 75 percent load is 88.4 percent efficient. The facility manager
standard-efficiency counterparts. (Specify “inverter rated” finds a premium-efficiency motor with an efficiency of
when purchasing a motor for use with a variable speed drive.) 92.4 percent at 75 percent load with an installed cost of $650.
The utility rate is $0.08 per kWh, and there is no demand
Table 2 was created in 2003 to compare various-sized charge. The following calculations show the payback for the
motors. The comparison is based on replacing an in-service replacement:
standard-efficiency motor with a motor that meets the
requirements for a premium-efficiency designation. All Demand savings (kW) = (hp x 0.746) x LF x (1/Eexist – 1/Ereplace)
motors are 230V/460V, 1800 RPM (four poles), TEFC, = (10 x 0.746) x (0.75) x (1 ÷ 0.884 – 1 ÷ 0.924)
general purpose, NEMA Design A or B types. Cost compar- = 0.27 kW
isons are based on 7500 annual hours at 75 percent of rated Annual cost savings = 0.27 kW x 6000 hours x $0.08 per kWh
= $132
power (load factor = 75 percent), and a $0.06/kWh utility
Payback = $650 ÷ $132
rate. A dealer discount of 20 percent was assumed for the
= 4.9 years
purchase price.
For the case study information (10 hp, efficiency gain of
Case Study 4 percent), Graph 3 shows the effect of operating hours and
utility rates on the simple payback when replacing a standard
A three-phase, 10-hp motor running for 6000 hours per year motor with a premium-efficiency motor.
has an efficiency of 87 percent at full load. To find the load
factor, an electrician takes the following measurements: Graph 3 – Payback vs. Operating Hours for Different Utility Rates
Vab = 463 V Ia = 11.5 A PFa = 0.70
12 $0.05/kWh
Vbc = 467 V Ib = 11.0 A PFb = 0.72 $0.08/kWh
Payback Period (years)

Vca = 459 V Ic = 11.4 A PFc = 0.71 10 $0.10/kWh

8
Using the equations on page 3, Boxes 1 to 4 , the load factor 6
is calculated to be 75 percent, as follows: 4

V = (463 + 467 + 459) ÷ 3 = 463 V 2

I = (11.5 + 11.0 + 11.4) ÷ 3 = 11.3 A 0

4000

4500

5000

5500

6000

6500

7000

7500

8000

8500
PF = (0.70 + 0.72 + 0.71) ÷ 3 = 0.71
Operating Hours
PI = (463 x 11.3 x 0.71 x 1.732) ÷ 1000 = 6.43 kW
PIR = (10 x 0.746) ÷ 0.87 = 8.57 kW

LF = 6.43 ÷ 8.57 = 0.75

The Energy Innovators Initiative, part of Natural Resources
Canada’s Office of Energy Efficiency, helps commercial
businesses and public institutions improve energy efficiency
and reduce greenhouse gas emissions that contribute
climate change.

For more information, contact

Energy Innovators Initiative, Office of Energy Efficiency, Natural Resources Canada, 580 Booth Street, 18th Floor, Ottawa ON K1A 0E4
Tel.: 1 877 360-5500 (toll-free) • Fax: (613) 947-4121 • E-mail: info.services@nrcan.gc.ca • Web site: oee.nrcan.gc.ca/eii
TTY: 613-996-4397 (Teletype for the hearing-impaired)

Leading Canadians to Energy Efficiency at Home, at Work and on the Road

The Office of Energy Efficiency of Natural Resources Canada
strengthens and expands Canada’s commitment to energy efficiency
in order to help address the challenges of climate change.

© Her Majesty the Queen in Right of Canada, 2004

Cat. No. M144-21/2003E
ISBN 0-662-35668-3 Recyled
Aussi disponible en français sous le titre : Moteurs à rendement supérieur paper