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eLibrary > BS EN IEC 61800-9-2:2025 Adjustable speed electrical power drive systems (PDS) - Ecodesign for motor systems. Energy efficiency determination and classification >

BS EN IEC 61800-9-2:2025 Adjustable speed electrical power drive systems (PDS) - Ecodesign for motor systems. Energy efficiency determination and classification, 2025

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BS EN IEC 61800-9-2:2025 Adjustable speed electrical power drive systems (PDS) - Ecodesign for motor systems. Energy efficiency determination and classification, 2025

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European foreword
Endorsement notice
Annex ZA (normative) Normative references to international publications with their corresponding European publications [Go to Page]
English [Go to Page]
CONTENTS
FOREWORD
INTRODUCTION
1 Scope
2 Normative references
3 Terms, definitions and symbols [Go to Page]
3.1 Terms and definitions
Figures [Go to Page]
Figure 1 – Example of complete drive module (CDM) built by sub drive modules (SDM)
Figure 2 – Illustration of the extended product with included motor system
Figure 3 – Torque-speed-characteristic of servo PDS
3.2 Symbols
4 PDS efficiency, reference CDM (RCDM) and reference motor (RM) [Go to Page]
4.1 General
4.2 Reference operating points of the PDS, RCDM, RM and associated losses
Figure 4 – Illustration of the operating points (shaft speed, torque) forthe determination of relative losses of the power drive system (PDS)
Figure 5 – Illustration of the operating points (shaft speed, torque) forthe determination of relative losses of the reference motor (RM)
4.3 Combining PDS losses with the driven equipment – Workflow for the semi-analytical model (SAM)
Figure 6 – Illustration of the operating points (relative motor stator frequency,relative torque current) for the determination of lossesof the reference complete drive module (RCDM)
Figure 7 – Illustration of the workflow to determine the energyefficiency index (EEI) of an extended product
4.4 IE Classes of line-fed motors
4.5 IE Classes of converter-fed motors
4.6 IE Classes of frequency converters (complete drive modules, CDM)
Figure 8 – Illustration how to combine different data sources to determine the energy efficiency index (EEI) of an extended product
4.7 IES Classes of a PDS
4.8 Consistency of IE and IES Classes
Figure 9 – Metrical relation
4.9 Determination of the IES class of a PDS by application of "reference" and "test" devices and guidance for the providers
5 Determination of CDM, motor and PDS loss by calculation [Go to Page]
5.1 General
Figure 10 – Guidance for CDM and motor providers for the usage of "test" and "reference" devices to determine the IE/IES classes
5.2 CDM losses [Go to Page]
5.2.1 General procedure and definition of the CDM and the test load
Figure 11 – Illustration of a typical CDM and test load
Tables [Go to Page]
Table 1 – Minimum test load currents at different points of operation
Table 2 – Test load displacement factor between fundamental output current and fundamental output voltage at different points of operation [Go to Page]
5.2.2 Overall CDM losses
5.2.3 Loss determination of CDMs composed by combination of submodules
Figure 12 – Example of relative losses pL,CDM of the 9,95 kVA RCDM
Table 3 – Example of relative losses of the 400 V/9,95 kVA reference CDMat the operating points described in Figure 6 [Go to Page]
5.2.4 Validation of loss calculation method
5.3 Motor losses [Go to Page]
5.3.1 General
Table 4 – Active SDIM power ratio to be used for loss calculationat the CDM operating points [Go to Page]
5.3.2 Additional harmonic losses of three-phase asynchronous motors fed by a CDM
5.3.3 Motor loss data
5.4 Power drive system (PDS) losses [Go to Page]
5.4.1 PDS losses
Table 5 – Reference parameter for Formula (13)
Table 6 – Relative losses of the 400 V/7,5 kW PDS [Go to Page]
5.4.2 PDS losses at different switching frequencies
Figure 13 – Example of the relative power losses of PDSas function of speed and torque
Figure 14 – Example representation of the relative power losses versusswitching frequency of a 7,5 kW to 11 kW PDS
5.5 PDS losses for regenerative operation
5.6 Losses of motor starters
6 Limits of IE and IES Classes [Go to Page]
6.1 General
Figure 15 – Example of a CDM with resistor for dissipating generated power
6.2 CDM
Table 7 – Reference CDM losses for class IE1 definition
6.3 Correction factors for CDMs with modified functionality [Go to Page]
6.3.1 General
Figure 16 – Illustration of IE Classes for a CDM [Go to Page]
6.3.2 Correction factors
6.3.3 Reference losses and loss determination concept for CDMs and SDOMs with multiple AC outputs
Table 8 – Correction factors for different CDM, SDIM and SDOM characteristics
Figure 17 – Topology of a CDM with multiple AC outputs
6.4 Motor
6.5 PDS
7 Loss determination [Go to Page]
7.1 General
7.2 Type testing of CDM or SDM for IE classification
Figure 18 – Losses of CDM or SDM are provided as the sum of the determined lossesplus the uncertainty of the determination method
7.3 Type testing of PDS for IES classification
7.4 Determination of losses by calculation [Go to Page]
7.4.1 CDM or SDM losses by calculation
7.4.2 PDS losses by calculation
7.5 Determination of losses by measurement, Input-output method [Go to Page]
7.5.1 Instrumentation
7.5.2 Test conditions
7.5.3 Input-output measurement of CDM losses
Figure 19 – Input-output measurement setup for determination of CDM losses
Figure 20 – Order of CDM measurements from [1] to [8] [Go to Page]
7.5.4 Input-output measurement of SDIM losses
Figure 21 – Input-output measurement setup for determination of SDIM losses [Go to Page]
7.5.5 Input-output measurement of SDOM losses
Figure 22 – Input-output measurement setup for determination of SDOM losses [Go to Page]
7.5.6 Input-output measurement of PDS losses
Figure 23 – Input-output measurement setup for PDS losses
7.6 Calorimetric measurement of CDM losses
Figure 24 – Order of PDS measurements from [1] to [8]
7.7 Flowcharts for test procedures
Figure 25 – Calorimetric measurement setup for determining CDM losses
Figure 26 – Determination of IE classification for CDM andloss determination for part load operating points
Figure 27 – Determination of IES classification for PDS andloss determination for part load operating points
8 Requirements for the user’s documentation [Go to Page]
8.1 General
Table 9 – Information requirements
8.2 Information for selection
8.3 Information for determination of energy efficiency classification
8.4 Information on the determination of additional energy losses and part load conditions [Go to Page]
8.4.1 General
8.4.2 Losses in part load conditions
8.4.3 Losses of accessories and options
8.4.4 Losses in stand-by mode
8.4.5 Regenerative mode
8.4.6 Characteristics and correction factors
Annex A (informative)Losses of RCDM and example of IES class limit determination [Go to Page]
A.1 Relative loss tables
Table A.1 – Relative losses (%) of reference CDMs (IE1) at different power ratingsat the operating points described in Figure 6
A.2 Calculation of relative losses for IES classes [Go to Page]
A.2.1 General
A.2.2 Determination of CDM relative losses
Table A.2 – Relative losses of the 9,95 kVA CDM according to Table A.1 [Go to Page]
A.2.3 Determination of motor relative losses
A.2.4 Summation of PDS relative losses
Annex B (informative)Description of the elements of an extended product using PDSwith regard to their impact on losses [Go to Page]
B.1 General
B.2 Losses in the mains cabling and feeding section
Figure B.1 – Overview of the extended product and energy flow
Figure B.2 – Equivalent circuit of the mains and mains cabling
B.3 Input filter [Go to Page]
B.3.1 High frequency EMI filter
B.3.2 Low frequency line harmonics filter
Figure B.3 – Illustration of a single-phase line harmonics filter
B.4 Input converter [Go to Page]
B.4.1 General
B.4.2 Diode rectifier
B.4.3 Active infeed converter
Figure B.4 – PDS with a diode rectifier input converter
Figure B.5 – PDS with a standard AIC input converter
Figure B.6 – PDS with a F3E-AIC input converter without line choke [Go to Page]
B.4.4 Power factor of the input converter
Figure B.7 – Typical waveform of a diode rectifier line current
Table B.1 – Typical values of λ for different input converter topologies [Go to Page]
B.4.5 Sub drive input module (SDIM)
B.5 DC link
Figure B.8 – DC link circuit
B.6 Output inverter [Go to Page]
B.6.1 General
Figure B.9 – DC link circuit with additional DC chokes [Go to Page]
B.6.2 Sub drive output model (SDOM)
B.7 Output filter and motor cables [Go to Page]
B.7.1 General
Figure B.10 – Output inverter of the PDS [Go to Page]
B.7.2 Sine wave filters
Figure B.11 – Motor cable and optional output filter of the PDS
Figure B.12 – Typical waveform of inverter output voltage and motorvoltage when using a sine wave output filter [Go to Page]
B.7.3 dV/dt filters and motor chokes
B.7.4 High frequency EMI motor filters
B.7.5 Motor cables
B.8 Motor
B.9 Mechanical load
B.10 Control and standby losses
B.11 Cooling losses [Go to Page]
B.11.1 Primary cooling losses
B.11.2 Secondary cooling losses
Annex C (informative)Mathematical model for CDM losses [Go to Page]
C.1 General
C.2 Output inverter losses [Go to Page]
C.2.1 General
C.2.2 Transistor on state losses
Table C.1 – Reference parameters for Formula (C.1) [Go to Page]
C.2.3 Freewheeling diode on state losses
C.2.4 Transistor switching losses
Table C.2 – Variables for Formula (C.1)
Table C.3 – Reference parameters for Formula (C.2) [Go to Page]
C.2.5 Freewheeling diode switching losses
Table C.4 – Reference parameters for Formula (C.3)
Table C.5 – Reference parameters for Formula (C.4) [Go to Page]
C.2.6 Output inverter total losses
C.3 Input converter losses [Go to Page]
C.3.1 Active infeed converter
C.3.2 Diode rectifier
C.4 Input choke losses
Table C.6 – Reference parameters for Formula (C.6)
Table C.7 – Variables for Formula (C.6)
Table C.8 – Reference parameters for Formula (C.7)
C.5 DC link losses
C.6 Current conductor losses
Table C.9 – Reference parameters for Formula (C.8)
Table C.10 – Reference parameters for Formula (C.9)
C.7 Control and standby losses
C.8 Cooling loss factor
C.9 Other CDM losses
Table C.11 – Reference parameter for Formula (5)
Table C.12 – Reference parameter for Formula (C.10)
Annex D (informative)Converter topology [Go to Page]
D.1 General
D.2 Voltage source output inverter topologies different from those mathematically described in Clause C.2
D.3 Voltage source input converter topologies different from those mathematically described in Clause C.3
D.4 CDM topologies different from voltage source type
Annex E (informative)Interpolation of motor losses and motor current [Go to Page]
E.1 General
E.2 Relative and reference values
E.3 Motor connections and operating ranges
Figure E.1 – Normalized torque and speed of ranges a and b for connection Y or D
E.4 Interpolation of motor losses
Figure E.2 – Normalized torque and speed of ranges a and b for connection Y --> D
Figure E.3 – Normalized torque and speed of range a for connection Y --> YY
Figure E.4 – Normalized losses of an exemplary motor in connection Y or D
Figure E.5 – Normalized losses of an exemplary motor in connection Y --> D
Figure E.6 – Normalized losses of an exemplary motor in connection Y --> YY
Figure E.7 – Efficiency map of the exemplary motor in connection Y or D
E.5 Interpolation of motor current
Figure E.8 – Efficiency map of the exemplary motor in connection Y --> D
Figure E.9 – Efficiency map of the exemplary motor in connection Y --> YY
Figure E.10 – Line-current of the exemplary motor in connection Y or D
Figure E.11 – Line-current of the exemplary motor in connection Y --> D
E.6 Determination of the interpolation coefficients [Go to Page]
E.6.1 General
E.6.2 Analytical determination
Figure E.12 – Line-current of the exemplary motor in connection Y --> YY
Table E.1 – Normative operating points of IEC 60034-2-3
Figure E.13 – Standardized operating points of IEC 60034-2-3 [Go to Page]
E.6.3 Numerical determination
E.7 Achievable accuracies
E.8 Typical induction motor efficiency
Table E.2 – Interpolation coefficients of typical 4-pole IE2 induction machines
Table E.3 – Interpolation coefficients of typical 2-pole IE2 induction machines
Table E.4 – Interpolation coefficients of typical 4-pole IE3 induction machines
Table E.5 – Interpolation coefficients of typical 4-pole IE4 induction machines
Table E.6 – Interpolation coefficients of typical 4-pole IE5 induction machines
Annex F (informative)Application example for loss calculations of a CDM and a PDS [Go to Page]
F.1 General
F.2 CDM loss determination [Go to Page]
F.2.1 General
Figure F.1 – Segments of operating points [Go to Page]
F.2.2 Loss determination by two-dimensional interpolation of losses of neighbouring loss points
Figure F.2 – Two-dimensional interpolation
Table F.1 – Relative losses of a 400 V/9,95 kVA example CDM (IE1)at the predefined operating points [Go to Page]
F.2.3 Loss determination by the mathematical model described in Annex C
Table F.2 – Parameters of the example CDM
F.3 Loss determination of the motor
Table F.3 – Results of the CDM calculation according to the mathematical model
Table F.4 – Comparison of different loss evaluation methods
Table F.5 – Loss data of the 7,5 kW example motor
F.4 Loss determination of the PDS
F.5 Determination of part load factors for SDIMs
Table F.6 – Calculated part-load factors for SDIM part load operation points
F.6 Application examples of reference losses and efficiency classes for modified functionality [Go to Page]
F.6.1 General
F.6.2 Example 1 – IE classification of an SDIM
F.6.3 Example 2 – IE classification of an SDOM
F.6.4 Example 3 – IE classification of a CDM with regenerative capability and sinewave output filter
Annex G (informative)Uncertainty of loss determination method [Go to Page]
G.1 General
G.2 Calculation of uncertainty at randomly occurring errors
G.3 Comparison of uncertainties for different loss determination methods
Annex H (informative)Calorimetric measurement for CDM losses [Go to Page]
H.1 General
H.2 Calorimeter with two chambers with air as a cooling medium
Figure H.1 – One-step calorimetric measurement setup for comparative loss measurement (CDM and heating resistor are loaded simultaneously)
H.3 Calorimeter with one chamber with air as a cooling medium
Figure H.2 – Two-step calorimetric measurement setup for comparative loss measurement (CDM and heating resistor are not loaded simultaneously)
H.4 Calorimeter with liquid as a cooling medium
Figure H.3 – Liquid cooled calorimetric measurement setup for CDM loss measurement
Annex I (informative)PDS loss calculation above rated speed and torque [Go to Page]
I.1 General
I.2 Operating points above rated torque
I.3 Operating points above rated speed [Go to Page]
I.3.1 General
I.3.2 Dependency of motor losses on the CDM performance
I.3.3 Dependency of CDM on the motor performance
I.3.4 PDS loss calculation in the field weakening range up to 200 % of rated speed
Annex J (informative)Explanation for correction factors for the reference losses in Table 8 [Go to Page]
J.1 General
J.2 CDM [Go to Page]
J.2.1 CDM without regenerative capability
J.2.2 CDM with regenerative capability
J.2.3 CDM with DFU ≤ 10 %
J.2.4 CDM with a rated input voltage ≤ 250 V (three phase)
J.2.5 CDM with single phase input
J.3 SDIM and SDOM [Go to Page]
J.3.1 General
J.3.2 SDIM without regenerative capability
J.3.3 SDIM with regenerative capability
J.3.4 SDOM
J.4 CDM, SDIM and SDOM with external cooling
J.5 CDM and SDOM with multiple AC outputs
Bibliography [Go to Page]

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