prEN IEC 61800-9-2:2022

SLOVENSKI STANDARD
oSIST prEN IEC 61800-9-2:2023
01-januar-2023

Električni pogonski sistemi z nastavljivo hitrostjo - 9-2. del: Okoljsko primerno

Adjustable speed electrical power drive systems - Part 9-2: Ecodesign for motor systems

Drehzahlveränderbare elektrische Antriebe - Teil 9-2: Ökodesign für Antriebssysteme,

Motorstarter, Leistungselektronik und deren angetriebene Einrichtungen - Indikatoren für

Entraînements électriques de puissance à vitesse variable - Partie 9-2: Ecoconception

l'électronique de puissance et de leurs applications entraînées - Indicateurs d'efficacité

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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Adjustable speed electrical power drive systems – Part 9-2: Ecodesign for motor systems – Energy efficiency

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CONTENTS ............................................................................................................................ 1

FOREWORD ........................................................................................................................... 9

INTRODUCTION ................................................................................................................... 11

1 Scope ............................................................................................................................ 12

2 Normative references .................................................................................................... 13

3 Terms, definitions, symbols and abbreviated terms ........................................................ 14

3.1 Terms and definitions ............................................................................................ 14

3.2 Symbols and abbreviated terms ............................................................................ 18

4 PDS efficiency, reference CDM (RCDM) and reference motor (RM) ............................... 26

4.1 General ................................................................................................................. 26

4.2 Reference operating points of the PDS, RCDM, RM and associated losses ........... 27

analytical model (SAM) ......................................................................................... 29

4.4 IE classes of line-fed motors ................................................................................. 31

4.5 IE classes of converter-fed motors ........................................................................ 31

4.6 IE Classes of frequency converters (complete drive modules, CDM) ..................... 31

4.7 IES Classes of a PDS ........................................................................................... 31

4.8 Consistency of IE and IES classes ........................................................................ 31

"test" devices and guidance for the manufacturers ................................................ 32

5 Determination of CDM, motor and PDS loss by calculation ............................................ 33

5.1 General ................................................................................................................. 33

5.2 CDM losses .......................................................................................................... 34

5.2.1 General procedure and definition of the CDM and the test load ..................... 34

5.2.2 Overall CDM losses ....................................................................................... 36

5.2.3 Loss determination of CDMs composed by combination of submodules ......... 37

5.2.4 Validation of loss calculation method ............................................................. 39

5.3 Motor losses ......................................................................................................... 39

5.3.1 General ......................................................................................................... 39

a CDM ........................................................................................................... 39

5.3.3 Motor loss data .............................................................................................. 40

5.4 Power Drive System (PDS) ................................................................................... 40

5.4.1 PDS losses .................................................................................................... 40

5.4.2 PDS losses at different switching frequencies ................................................ 41

5.5 PDS losses for regenerative operation .................................................................. 42

5.6 Losses of motor starters ....................................................................................... 43

6 Limits of IE and IES classes .......................................................................................... 43

6.1 General ................................................................................................................. 43

6.2 CDM ..................................................................................................................... 43

6.3 Correction factors for CDMs with modified functionality ......................................... 46

6.3.1 General ......................................................................................................... 46

6.3.2 Correction factors .......................................................................................... 47

multiple a.c. outputs ...................................................................................... 48

6.4 Motor .................................................................................................................... 49

6.5 PDS ...................................................................................................................... 49

7 Loss determination ........................................................................................................ 50

7.1 General ................................................................................................................. 50

7.2 Type testing of CDM or SDM for IE classification .................................................. 51

7.3 Type testing of PDS for IES classification ............................................................. 52

7.4 Determination of losses by calculation .................................................................. 52

7.4.1 CDM or SDM losses by calculation ................................................................ 52

7.4.2 PDS losses by calculation .............................................................................. 53

7.5 Determination of losses by measurement, Input-output method ............................. 53

7.5.1 Instrumentation .............................................................................................. 53

7.5.2 Test conditions .............................................................................................. 54

7.5.3 Input-output measurement of CDM losses ..................................................... 55

7.5.4 Input-output measurement of SDIM losses ..................................................... 57

7.5.5 Input-output measurement of SDOM losses ................................................... 58

7.5.6 Input-output measurement of PDS losses ...................................................... 59

7.6 Calorimetric measurement of CDM losses ............................................................. 61

7.7 Flowcharts for test procedures .............................................................................. 62

8 Requirements for the user’s documentation ................................................................... 65

8.1 General ................................................................................................................. 65

8.2 Information for selection ....................................................................................... 66

8.3 Information for determination of energy efficiency classification ............................ 66

conditions ............................................................................................................. 66

8.4.1 General ......................................................................................................... 66

8.4.2 Losses in part load conditions ........................................................................ 66

8.4.3 Losses of accessories and options ................................................................ 67

8.4.4 Losses in stand-by mode ............................................................................... 67

8.4.5 Losses in regenerative mode ......................................................................... 67

8.4.6 Characteristics and correction factors ............................................................ 67

Annex A (informative) Losses of RCDM and example of IES class limit determination.......... 68

A.1 Relative loss tables ............................................................................................... 68

A.2 Calculation of relative losses for IES classes ........................................................ 69

A.2.1 Determination of CDM relative losses ............................................................ 69

A.2.2 Determination of Motor relative losses ........................................................... 69

A.2.3 Summation of PDS relative losses ................................................................. 70

Annex B (informative) Description of the elements of an extended product using PDS

with regard to their impact on losses.............................................................................. 71

B.1 General ................................................................................................................. 71

B.2 Losses in the mains cabling and feeding section ................................................... 71

B.3 Input filter ............................................................................................................. 73

B.3.1 High frequency EMI filter ............................................................................... 73

B.3.2 Low frequency line harmonics filter ................................................................ 73

B.4 Input converter ...................................................................................................... 74

B.4.1 General ......................................................................................................... 74

B.4.2 Diode rectifier ................................................................................................ 74

B.4.3 Active infeed converter .................................................................................. 74

B.4.4 Power factor of the input converter ................................................................ 76

B.4.5 Sub Drive Input Module (SDIM) ..................................................................... 76

B.5 d.c. link ................................................................................................................. 77

B.6 Output inverter ...................................................................................................... 78

B.6.1 General ......................................................................................................... 78

B.6.2 Sub Drive Output Model (SDOM) ................................................................... 79

B.7 Output filter and motor cables ............................................................................... 79

B.7.1 General ......................................................................................................... 79

B.7.2 Sine wave filters ............................................................................................ 79

B.7.3 dV/dt filters and motor chokes ........................................................................ 80

B.7.4 High frequency EMI motor filters .................................................................... 81

B.7.5 Motor cables .................................................................................................. 81

B.8 Motor .................................................................................................................... 81

B.9 Mechanical load .................................................................................................... 81

B.10 Control and standby losses ................................................................................... 81

B.11 Cooling losses ...................................................................................................... 82

B.11.1 Primary cooling losses ................................................................................... 82

B.11.2 Secondary cooling losses .............................................................................. 82

Annex C (Informative) Mathematical model for CDM losses ................................................. 83

C.1 Output inverter losses ........................................................................................... 83

C.1.1 General ......................................................................................................... 83

C.1.2 Transistor on state losses .............................................................................. 83

C.1.3 Freewheeling diode on state losses ............................................................... 84

C.1.4 Transistor switching losses ............................................................................ 84

C.1.5 Freewheeling diode switching losses ............................................................. 85

C.1.6 Output inverter total losses ............................................................................ 85

C.2 Input converter losses ........................................................................................... 86

C.2.1 Active infeed converter .................................................................................. 86

C.2.2 Diode rectifier ................................................................................................ 86

C.3 Input choke losses ................................................................................................ 87

C.4 d.c. link losses ...................................................................................................... 87

C.5 Current conductor losses ...................................................................................... 88

C.6 Control and standby losses ................................................................................... 88

C.7 Cooling loss factor ................................................................................................ 88

C.8 Other CDM losses ................................................................................................. 89

Annex D (informative) Converter topology ............................................................................ 90

D.1 General ................................................................................................................. 90

mathematically described in Annex C.1 ................................................................. 90

mathematically described in Annex C.2 ................................................................. 90

D.4 CDM topologies different from voltage source type ............................................... 90

Annex E (informative) Interpolation of motor losses and motor current ................................. 92

E.1 General ................................................................................................................. 92

E.2 Relative and reference values ............................................................................... 92

E.3 Motor connections and operating ranges ............................................................... 93

E.4 Interpolation of motor losses ................................................................................. 94

E.5 Interpolation of motor current ................................................................................ 97

E.6 Determination of the interpolation coefficients ....................................................... 99

E.6.1 Analytical determination................................................................................. 99

E.6.2 Numerical determination .............................................................................. 101

E.7 Typical induction motor efficiency ....................................................................... 102

Annex F (informative) Application example for loss calculations of a CDM and a PDS ....... 108

F.1 General ............................................................................................................... 108

F.2 CDM loss determination ...................................................................................... 108

F.2.1 General ....................................................................................................... 108

neighbouring loss points .............................................................................. 109

F.2.3 Loss determination by the mathematical model described in Annex C .......... 112

F.3 Loss determination of the motor .......................................................................... 114

F.4 Loss determination of the PDS ............................................................................ 115

F.5 Determination of part load factors for SDIMs ....................................................... 116

functionality ........................................................................................................ 116

F.6.1 Example 1 – IE classification of a SDIM ....................................................... 116

F.6.2 Example 2 – IE classification of a SDOM ..................................................... 117

sinewave output filter ................................................................................... 118

Annex G (informative) Uncertainty of loss determination method........................................ 119

G.1 General ............................................................................................................... 119

G.2 Calculation of uncertainty at randomly occurring errors ....................................... 119

G.3 Comparison of uncertainties for different loss determination methods ................. 119

Annex H (informative) Calorimetric measurement for CDM losses ...................................... 120

H.1 General ............................................................................................................... 120

H.2 Calorimeter with two chambers with air as a cooling medium .............................. 120

H.3 Calorimeter with one chamber with air as a cooling medium ............................... 121

H.4 Calorimeter with liquid as a cooling medium ........................................................ 122

Annex I (informative) PDS loss calculation above rated speed and torque ......................... 123

I.1 General ............................................................................................................... 123

I.2 Operating points above rated torque ................................................................... 123

I.3 Operating points above rated speed .................................................................... 123

I.3.1 General ....................................................................................................... 123

I.3.2 Dependency of motor losses on the CDM performance ................................ 123

I.3.3 Dependency of CDM on the motor performance ........................................... 124

speed .......................................................................................................... 124

Bibliography ........................................................................................................................ 126

Figure 1 – Example of Complete Drive Module (CDM) built by Sub Drive Modules (SDM) ..... 15

Figure 2 – Illustration of the extended product with included motor system ........................... 16

Figure 3 – Torque-speed-characteristic of servo PDS ........................................................... 17

determination of relative losses of the power drive system (PDS) ......................................... 27

determination of relative losses of the reference motor (RM)................................................. 28

Figure 6 – Illustration of the operating points (relative motor stator frequency, relative

torque current) for the determination of losses of the reference complete drive module

(RCDM) ................................................................................................................................ 28

Figure 7 – Illustration of the workflow to determine the energy efficiency index (EEI) of

an extended product ............................................................................................................. 30

Figure 8 – Illustration how to combine different data sources to determine the energy

efficiency index (EEI) of an extended product ....................................................................... 30

Figure 9 – Metrical relation of (a) IE classes and (b) IES classes .......................................... 32

"reference" devices to determine the IE/IES classes ............................................................. 33

Figure 11 – Illustration of a typical CDM and test load .......................................................... 34

Figure 12 – Relative losses p of the 9,95 kVA RCDM ................................................. 37

Figure 13 – Example of the relative power losses of PDS as function of speed and

torque ................................................................................................................................... 41

Figure 14 – Example of the relative power losses versus switching frequency....................... 42

Figure 15 – Example of a CDM with resistor for dissipating generated power ........................ 43

Figure 16 – Illustration of IE classes for a CDM .................................................................... 45

Figure 17 – Topology of a CDM with multiple a.c. outputs ..................................................... 48

Figure 18 – Losses of CDM or SDM are provided as the sum of the determined losses

plus the uncertainty of the determination method .................................................................. 52

Figure 19 – Input-output measurement setup for determination of CDM losses ..................... 56

Figure 21 – Input-output measurement setup for determination of SDIM losses .................... 58

Figure 22 – Input-output measurement setup for determination of SDOM losses ................... 59

Figure 23 – Input-output measurement setup for PDS losses ................................................ 60

Figure 24 – Order of PDS measurements from [1] to [8] ........................................................ 61

Figure 25 – Calorimetric measurement setup for determining CDM losses ............................ 62

Figure 26 – Determination of IE classification for CDM and loss determination for part

load operating points ............................................................................................................ 63

Figure 27 – Determination of IES classification for PDS and loss determination for part

load operating points ............................................................................................................ 64

Figure B.1 – Overview of the extended product and energy flow ........................................... 71

Figure B.2 – Equivalent circuit of the mains and mains cabling ............................................. 72

Figure B.3 – Illustration of a single-phase line harmonics filter .............................................. 73

Figure B.4 – PDS with a diode rectifier input converter ......................................................... 74

Figure B.5 – PDS with a standard AIC input converter .......................................................... 75

Figure B.6 – PDS with a F3E-AIC input converter without line choke ..................................... 75

Figure B.7 – Typical waveform of a diode rectifier line current .............................................. 76

Figure B.8 – d.c. link circuit................................................................................................... 77

Figure B.9 – d.c. link circuit with additional d.c. chokes ......................................................... 78

Figure B.10 – Output inverter of the PDS .............................................................................. 78

Figure B.11 – Motor cable and optional output filter of the PDS ............................................ 79

using a sine wave output filter ............................................................................................... 80

Figure E.1 – Normalized torque and speed of Ranges a and b for Connection Y or D. .......... 93