5A-i APPENDIX 5A. ENGINEERING DATA

TABLE OF CONTENTS

5A.1 INTRODUCTION .............................................................................................................. 1

5A.2 BASELINE DESIGN OPTI ONS ........................................................................................ 1

5A.3 COST-EFFICIENCY RESULTS ....................................................................................... 1

5A.4 COST-EFFICIENCY RELATIONSHIP VERIFICATION ............................................... 1

5A.5 DESIGN SPECIFICATIONS OF BASELINE POLYPHASE MOTOR ........................... 4

5A.5.1 Stator Dimensions ................................................................................................... 4

5A.5.2 Rotor Dimensions ................................................................................................... 4

5A.5.3 Rotor Slot Dimensions ............................................................................................ 4 5A.5.4 Ring & Coil Data .................................................................................................... 5

5A.5.5 Electrical Data ......................................................................................................... 5 5A.5.6 Load Speed & Slip Info .......................................................................................... 5

5A.5.7 No Load Performance ............................................................................................. 5

5A.5.8 Locked Rotor Data .................................................................................................. 5

5A.5.9 Breakdown Load Parameters .................................................................................. 6

5A.5.10 Reactance Values .................................................................................................. 6 5A.5.11 Winding Information............................................................................................. 6 5A.5.12 Magnetic Circuit Data ........................................................................................... 7

5A.6 DESIGN SPECIFICATIONS OF POLYPHASE TSL 5 (EL 5 SPACE CONSTRAINED)

DESIGN .............................................................................................................................. 8

5A.6.1 Stator Dimensions ................................................................................................... 8

5A.6.2 Rotor Dimensions ................................................................................................... 8

5A.6.3 Rotor Slot Dimensions ............................................................................................ 9 5A.6.4 Ring & Coil Data .................................................................................................... 9

5A.6.5 Electrical Data ......................................................................................................... 9 5A.6.6 Load Speed & Slip Info .......................................................................................... 9

5A.6.7 No Load Performance ........................................................................................... 10

5A.6.8 Locked Rotor Data ................................................................................................ 10

5A.6.9 Breakdown Load Parameters ................................................................................ 10

5A.6.10 Reactance Values ................................................................................................ 10 5A.6.11 Winding Information........................................................................................... 10 5A.6.12 Magnetic Circuit Data ......................................................................................... 11

5A.7 DESIGN SPECIFICATIONS OF BASELINE CSIR MOTOR ....................................... 13

5A.7.1 Stator Dimensions ................................................................................................. 13

5A.7.2 Rotor Dimensions ................................................................................................. 13

5A.7.3 Rotor Slot Dimensions .......................................................................................... 13 5A.7.4 Ring & Coil Data .................................................................................................. 13

5A.7.5 Electrical Data ....................................................................................................... 14 5A.7.6 Load Speed & Slip Info ........................................................................................ 14

5A.7.7 No Load Performance ........................................................................................... 14

5A.7.8 Locked Rotor Data ................................................................................................ 14

5A.7.9 Breakdown Load Parameters ................................................................................ 15

5A.7.10 Reactance Values ................................................................................................ 155A- ii

5A.7.11 Winding Information........................................................................................... 15 5A.7.12 Magnetic Circuit Data ......................................................................................... 16

5A.8 DESIGN SPECIFICATIONS OF CSIR TSL 7 (EL 7 SPACE CONSTRAINED)

DESIGN ............................................................................................................................ 17

5A.8.1 Stator Dimensions ................................................................................................. 17

5A.8.2 Rotor Dimensions ................................................................................................. 17 5A.8.3 Ring & Coil Data .................................................................................................. 18

5A.8.4 Electrical Data ....................................................................................................... 18 5A.8.5 Load Speed & Slip Info ........................................................................................ 19

5A.8.6 No Load Performance ........................................................................................... 19

5A.8.7 Locked Rotor Data ................................................................................................ 19

5A.8.8 Breakdown Load Parameters ................................................................................ 19

5A.8.9 Reactance Values .................................................................................................. 19 5A.8.10 Winding Information........................................................................................... 20 5A.8.11 Magnetic Circuit Data ......................................................................................... 20 5A.8.12 Overall Cost and Pricing Data ............................................................................ 21

5A.9 DESIGN SPECIFICATIONS OF BASELINE CSCR MOTOR ...................................... 22

5A.9.1 Stator Dimensions ................................................................................................. 22

5A.9.2 Rotor Dimensions ................................................................................................. 22

5A.9.3 Rotor Slot Dimensions .......................................................................................... 23 5A.9.4 Ring & Coil Data .................................................................................................. 23

5A.9.5 Electrical Data ....................................................................................................... 23 5A.9.6 Load Speed & Slip Info ........................................................................................ 24

5A.9.7 No Load Performance ........................................................................................... 24

5A.9.8 Locked Rotor Data ................................................................................................ 24

5A.9.9 Breakdown Load Parameters ................................................................................ 24

5A.9.10 Reactance Values ................................................................................................ 24 5A.9.11 Winding Information........................................................................................... 25 5A.9.12 Magnetic Circuit Data ......................................................................................... 25

5A.10 DESIGN SPECIFICATIONS OF CSCR TSL 7 (EL 3 SPACE CONSTRAINED)

DESIGN ............................................................................................................................ 27

5A.10.1 Stator Dimensions ............................................................................................... 27

5A.10.2 Rotor Dimensions ............................................................................................... 27

5A.10.3 Rotor Slot Dimensions ........................................................................................ 27 5A.10.4 Ring & Coil Data ................................................................................................ 27

5A.10.5 Electrical Data ..................................................................................................... 28 5A.10.6 Load Speed & Slip Info ...................................................................................... 28

5A.10.7 No Load Performance ......................................................................................... 28

5A.10.8 Locked Rotor Data .............................................................................................. 28

5A.10.9 Breakdown Load Parameters .............................................................................. 29

5A.10.10 Reactance Values .............................................................................................. 29 5A.10.11 Winding Information......................................................................................... 29 5A.10.12 Magnetic Circuit Data ....................................................................................... 30

5A.11 COMMODITY PRICES ................................................................................................... 31

5A.12 SCALING RELATIONSHIPS ......................................................................................... 385A- iii LIST OF TABLES

Table 2.1 Baseline Design Options .............................................................................................. 1 Table 11.1 Five-Year Commodity Prices in 2008$ ..................................................................... 32 Table 11.2 Commodity Price Impact on MSP for Space Constrained Polyphase Motors .......... 33 Table 11.3 Commodity Price Impact on MSP for Non-Space Constrained Polyphase Motors* 34 Table 11.4 Commodity Price Impact on MSP for Space Constrained CSIR Motors .................. 35 Table 11.5 Commodity Price Impact on MSP for Non-Space Constrained CSIR Motors* ........ 36 Table 11.6 Commodity Price Impact on MSP for Space Constrained CSCR Motors ................. 37 Table 11.7 Commodity Price Impact on MSP for Non-Space Constrained CSCR Motors* ...... 38 Table 12.1 Test Results for Polyphase Motors ............................................................................ 39

Table 12.2 Test Results for CSIR Motors .................................................................................... 39 Table 12.3 Scaled Efficiency Levels for Baseline Polyphase Small Electric Motors ................. 40 Table 12.4 Scaled Efficiency Levels for Baseline CSIR Small Electric Motors ......................... 40 Table 12.5 Scaled Efficiency Levels for Baseline CSCR Small Electric Motors ....................... 40

LIST OF FIGURES

Figure 4.1 Capacitor-Start, Induction-Run, 1⁄2 Horsepower, 4-Pole, 48-Frame Engineering

Analysis Curve with Tested Motor Results .................................................................. 2 Figure 4.2 Capacitor-Start, Capacitor-Run 3⁄4 Horsepower, 4-Pole, 56-Frame Engineering

Analysis Curve with Tested Motor Results .................................................................. 3 Figure 4.3 Polyphase 1 Horsepower, 4-Pole, 56-Frame Motor Engineering Analysis Curve with

Tested Motor Results .................................................................................................... 3 Figure 5.1 Torque and Output Power versus Speed for Baseline Polyphase Motor...................... 7 Figure 5.2 Current versus Speed for Baseline Polyphase Motor ................................................... 8 Figure 6.1 Torque and Output Power versus Speed for Efficiency Level 5, Space-Constrained,

Po lyphase Motor ......................................................................................................... 12 Figure 6.2 Current versus Speed for Efficiency Level 5, Space-Constrained, Polyphase Motor 12 Figure 7.1 Torque and Output Power versus Speed for Baseline CSIR Motor ........................... 16 Figure 7.2 Line Current versus Speed for Baseline CSIR Motor ................................................ 17 Figure 8.1 Torque and Output Power versus Speed for Efficiency Level 7, Space-Constrained,

CSIR Motor ................................................................................................................. 21 Figure 8.2 Line Current versus Speed for Efficiency Level 7, Space-Constrained, CSIR Motor 22 Figure 9.1 Torque and Output Power versus Speed for Baseline CSCR Motor .......................... 26 Figure 9.2 Line Current versus Speed for Baseline CSCR Motor ............................................... 26 Figure 10.1 Torque and Output Power versus Speed for Efficiency Level 3, Space-Constrained,

CSCR Motor ............................................................................................................... 30

Fi gure 10.2 Line Current versus Speed for Efficiency Level 3, Space-Constrained, CSCR Motor

..................................................................................................................................... 31 Figure 11.1 Commodity Price Impact on MSP for Space Constrained Polyphase Motors ......... 33 Figure 11.2 Commodity Price Impact on MSP for Non-Space Constrained Polyphase Motors . 34 Figure 11.3 Commodity Price Impact on MSP for Space Constrained CSIR Motors ................. 35 Figure 11.4 Commodity Price Impact on MSP for Non-Space Constrained CSIR Motors ........ 36 Figure 11.5 Commodity Price Impact on MSP for Space Constrained CSCR Motors ............... 37 Figure 11.6 Commodity Price Impact on MSP for Non-Space Constrained CSCR Motors ....... 385A-1 APPENDIX 5A ENGINEERING DATA

5A.1 INTRODUCTION

This appendix presents baseline specifications and detailed cost-efficiency results for each of the small electric motor product classes analyzed in the engineering analysis (chapter 5).

5A.2 BASELINE DESIGN OPTIONS

Table 2.1 shows the baseline design options for each product class analyzed. All changes to cost and efficiency are measured relative to this level in the engineering analysis. The representative motors chosen from each product class are: CSIR, 1⁄2 horsepower, four-pole; CSCR 3⁄4 horsepower, four-pole; and polyphase, 1 horsepower, four-pole motors. Refer to chapter 5 of the TSD for details about each baseline technology.

Table 2.1 Baseline Design Options

Parameter (Units) Polyphase CSIR CSCR
Efficiency (%) 77.2 57.7 71.0

Power Factor 71.6 59.4 68.6
Speed (RPM) 1714 1723 1735
Torque (in

- lbs ) 36.8 18.4 2 0.6
Current (A) 3.38 9.12 10.1

Core Steel 24M56 .028M56 24M56
Stack Height (in) 3.0 2 3

Rotor Material Al Al Al
Main Wire (AWG) 22 18.5 18
Auxiliary Wire (AWG) N/A 21.5 19
Start Capacitance (μF) N/A 333 433 Run Capacitance (μF) N/A N/A 7.5

Locked

- Rotor Torque (in

- lbs) 76.1 51.0 57.3

Locked

- Rotor Current (A) 16.6 38.0 53.2

Service Factor 1.15 1.25 1.25

5A.3 COST-EFFICIENCY RESULTS

For each product class analyzed in the engineering analysis, DOE had its subcontractor create higher efficiency designs above the baseline efficiency level. The subcontractor modeled these designs after the baseline design, but altered several design specifications within the limits provided by DOE.

5A.4 COST-EFFICIENCY RELATIONSHIP VERIFICATION

Once the cost-efficiency relationships were determined using the subcont ractor’s designs, DOE tested 2 to 3 additional motors in each product class to corroborate the results gleaned from the subcontractor’s design work . These motors all had the same pole configuration and horsepower rating as the representative product class, but they differed in rated efficiency from the previously tested baseline motor upon which the subcontractor based its designs. Figure 4.1 through Figure 4.3 show the results of these tested motors plotted with the cost-efficiency results5A-2

determined using the subcontractor’s modeled designs. The max -tech point has been removed

from these illustrations.

Figure 4.1 Capacitor-Start, Induction-Run, 1⁄2 Horsepower, 4-Pole, 48-Frame Engineering Analysis Curve with Tested Motor Results5A-3

Figure 4.2 Capacitor-Start, Capacitor-Run 3⁄4 Horsepower, 4-Pole, 56-Frame Engineering Analysis Curve with Tested Motor Results

Figure 4.3 Polyphase 1 Horsepower, 4-Pole, 56-Frame Motor Engineering Analysis Curve

with Tested Motor Results

The tested motors lie at or below the engineering analysis curves developed for the CSIR and CSCR product class es. This confirms that DOE’s cost -efficiency curves are sufficient in5A-4

estimating the actual cost of achieving an efficiency level above the baseline for these product classes. The tested motors from the polyphase product class also appear in-line with the engineering analysis curve; however these motors tested at an efficiency level below what DOE used for the baseline efficiency. As mentioned in TSD chapter 5, this was because the motor purchased as the baseline motor tested at an efficiency level higher than what it was listed at. Additionally, the motors in the graph above that are at lower efficiencies than the baseline tested at efficiencies lower than what they were listed at.

5A.5 DESIGN SPECIFICATIONS OF BASELINE POLYPHASE MOTOR

5A.5.1 Stator Dimensions

Lamination Steel Type Tempel M56 Length of the Stator Stack 3.0000 inch Stacking Factor of the Stator 0.9800

Stator Slot Insulation Thickness 0.0100 inch

Number of Stator Poles 4 Poles

Outside Diameter of the Stator 5.4870 inch

Number of Stator Slots 24

Inside Diameter of the Stator 3.1740 inch Thickness of mid slot separator 0.0000 inch Stator Slot Width Next to Gap 0.1800 inch

Stator Slot Width at Bottom of Slot 0.3130 inch Depth of Main Trapezoidal Part 0.6840 inch Depth of Slot Mouth 0.0260 inch Stator Slot Opening 0.1000 inch Depth of Tooth Tip 0.0300 inch Total Depth of Stator Slot 0.7400 inch

5A.5.2 Rotor Dimensions

Shaft Material Magnetic

Outside Diameter of the Rotor 3.1558 inch

Inside Diameter of the Rotor 0.9350 inch Length of the Rotor Stack 3.0100 inch Stacking Factor of the Rotor 0.9800

5A.5.3 Rotor Slot Dimensions

Closed Bridge, Trap w/ Round Bottom Depth of Rotor Slot Opening 0.0000 inch Width at Top of Rotor Slot 0.1400 inch

Width at Bottom of Rotor Slot 0.0700 inch Depth of Main Trapezoidal Part 0.1750 inch Depth of Slot Mouth 0.0100 inch Depth of Bridge 0.0000 inch Total Depth of Rotor Slot 0.2750 inch5A-5

Number of Rotor Slots 36 slots

5A.5.4 Ring & Coil Data

Inside Diameter of Ring 1 2.2000 inch Outside Diameter of Ring 1 2.9400 inch Axial Thickness at Outside of Ring 1 0.4250 inch Axial Thickness at Inside of Ring 1 0.4250 inch Inside Diameter of Ring 2 2.2000 inch Outside Diameter of Ring 2 2.9400 inch Axial Thickness at Outside of Ring 2 0.4250 inch Axial Thickness at Inside of Ring 2 0.4250 inch Conductivity of the Rotor Bar Material 0.5700 Conductivity of the End Ring Material 0.5700

5A.5.5 Electrical Data

Wire Insulation Type Heavy Terminal Voltage 230.00 Volts Turns per Coil in Slot 1 62 Turns Turns per Coil in Slot 2 27 Turns Winding Wire Size 22.0 AWG Line Frequency 60.0 Hz

Rotor Skew 1.50 bars Winding Operating Temperature 103.00 deg C Friction & Windage Loss at Idle Speed 4.1790 Watts Stray Load Loss 2.4 %

Wire Stretch Factor 1.030

5A.5.6 Load Speed & Slip Info

Specified Load Speed 1714.0 RPM Minimum Load Speed 0.0 RPM Speed Increment 20.0 RPM

5A.5.7 No Load Performance

Synchronous Speed 1800.0 RPM Actual No Load Speed 1799.3 RPM Actual No Load Phase Current 2.29 Amps No Load Phase Winding Current Density 2279.25 Amps/sq. in

5A.5.8 Locked Rotor Data

Locked Rotor Torque 76.11 lb- in Locked Rotor Phase Current 16.634 Amps Locked Rotor Phase Current Density 16543.70 A/sq. in.5A-6

5A.5.9 Breakdown Load Parameters

BreakDown Speed 1205.3 RPM BreakDown Torque 113.58 lb- in BreakDown Current 11.83 Amps BreakDown Output Power 1620.1 Watts BreakDown Output Power 2.1717 Hp BreakDown Efficiency 43.5 %

BreakDown Power Factor 78.925 BreakDown Input Power 3720.9 Watts Phase Current Density at BreakDown 11770.35 A/sq. in.

5A.5.10 Reactance Values

Primary Slot Leakage 0.9407 Ohms Secondary Slot Leakage 0.8460 Ohms End Leakage 0.5551 Ohms Skew Leakage 0.5852 Ohms Zig Zag Leakage 1.2111 Ohms Belt Leakage 0.1941 Ohms Primary Leakage Reactance 3.4861 Ohms Rotor Leakage 2.9066 Ohms Magnitizing Reactance 54.3967 Ohms

5A.5.11 Winding Information

Hot Rotor Resistance 2.2374 Ohms

Rotor Resistance Ratio 0.3500 Cold Winding Resistance 2.2125 Hot Winding Resistance 2.8765 Ohms Winding Distribution Factor 0.966 Total Winding Conductors per Phase 356.00 Conductors Effective Winding Conductors per Phase 343.9 Conductors

Slot 1 % Fill 50.12 %

Slot 2 % Fill 21.82 %

Slot 3 % Fill 0.00 %

Slot 4 % Fill 0.00 %

Slot 5 % Fill 0.00 %

Slot 6 % Fill 0.00 %

Slot 7 % Fill 0.00 %

Slot 8 % Fill 0.00 % Total Weight of the Copper 3.1936 lbs Electrical Area of One Rotor Bar 0.0261 sq. in. Electrical Area of All Rotor Bars 0.9386 sq. in. Weight of Stator Steel 13.3193 lbs Weight of Rotor Steel 6.0995 lbs Weight of Stator and Rotor Steel 19.4188 lbs5A-7

Weight of Rotor Aluminum 0.5348 lbs

5A.5.12 Magnetic Circuit Data

Magnetic Length of Air Gap 0.0115 inch Total Air Gap Flux per Pole 267.4 kilolines Flux Density in Air Gap 53.9 Klines/in^2 Flux Density in Stator Yoke 101.5 Klines/in^2 Flux Density in Stator Teeth 89.7 Klines/in^2 Flux Density in Rotor Yoke 50.5 Klines/in^2 Flux Density in Rotor Teeth 110.4 Klines/in^2 MMF Drop in Air Gap 194.2 A-T MMF Drop in Stator Yoke 20.8 A-T MMF Drop in Rotor Yoke 1.2 A-T MMF Drop in Statot Teeth 3.4 A-T MMF Drop in Rotor Teeth 16.1 A-T Total MMF Drop 235.6 A-T

Figure 5.1 Torque and Output Power versus Speed for Baseline Polyphase Motor5A-8 Figure 5.2 Current versus Speed for Baseline Polyphase Motor

5A.6 DESIGN SPECIFICATIONS OF POLYPHASE TSL 5 (EL 5 SPACE CONSTRAINED) DESIGN

5A.6.1 Stator Dimensions

Lamination Steel Type M 15 Length of the Stator Stack 3.6000 inch Stacking Factor of the Stator 0.9800

Stator Slot Insulation Thickness 0.0100 inch

Number of Stator Poles 4 Poles

Outside Diameter of the Stator 5.4870 inch

Number of Stator Slots 24

Inside Diameter of the Stator 3.1740 inch Thickness of mid slot separator 0.0000 inch Stator Slot Width Next to Gap 0.1800 inch

Stator Slot Width at Bottom of Slot 0.3130 inch Depth of Main Trapezoidal Part 0.6840 inch Depth of Slot Mouth 0.0260 inch Stator Slot Opening 0.1000 inch Depth of Tooth Tip 0.0300 inch Total Depth of Stator Slot 0.7400 inch

5A.6.2 Rotor Dimensions

Shaft Material Magnetic

Outside Diameter of the Rotor 3.1558 inch5A-9

Inside Diameter of the Rotor 0.9350 inch Length of the Rotor Stack 3.6000 inch Stacking Factor of the Rotor 0.9800

5A.6.3 Rotor Slot Dimensions

Closed Bridge, Trap w/ Round Bottom Depth of Rotor Slot Opening 0.0000 inch Width at Top of Rotor Slot 0.1400 inch

Width at Bottom of Rotor Slot 0.0700 inch Depth of Main Trapezoidal Part 0.1750 inch Depth of Slot Mouth 0.0100 inch Depth of Bridge 0.0000 inch Total Depth of Rotor Slot 0.2750 inch

Number of Rotor Slots 36 slots

5A.6.4 Ring & Coil Data

Inside Diameter of Ring 1 2.2000 in ch Outside Diameter of Ring 1 2.9400 inch Axial Thickness at Outside of Ring 1 0.5500 inch Axial Thickness at Inside of Ring 1 0.5500 inch Inside Diameter of Ring 2 2.2000 inch Outside Diameter of Ring 2 2.9400 inch Axial Thickness at Outside of Ring 2 0.5500 inch Axial Thickness at Inside of Ring 2 0.5500 inch Conductivity of the Rotor Bar Material 0.5700 Conductivity of the End Ring Material 0.5700

5A.6.5 Electrical Data

Wire Insulation Type Heavy Terminal Voltage 230.00 Volts Turns per Coil in Slot 1 44 Turns Turns per Coil in Slot 2 44 Turns Winding Wire Size 19.5 AWG Line Frequency 60.0 Hz

Rotor Skew 1.50 bars Winding Operating Temperature 103.00 deg C Friction & Windage Loss at Idle Speed 4.1790 Watts Stray Load Loss 2.4 %

Wire Stretch Factor 1.030

5A.6.6 Load Speed & Slip Info

Specified Load Speed 1719.0 RPM Minimum Load Speed 0.0 RPM Speed Increment 10.0 RPM5A-10

5A.6.7 No Load Performance

Synchronous Speed 1800.0 RPM Actual No Load Speed 1799.3 RPM Actual No Load Phase Current 1.97 Amps No Load Phase Winding Current Density 1082.30 Amps/sq. in

5A.6.8 Locked Rotor Data

Locked Rotor Torque 80.98 lb- in Locked Rotor Phase Current 16.388 Amps Locked Rotor Phase Current Density 9024.89 A/sq. in.

5A.6.9 Breakdown Load Parameters

BreakDown Speed 1188.7 RPM BreakDown Torque 124.23 lb- in BreakDown Current 11.92 Amps BreakDown Output Power 1747.7 Watts BreakDown Output Power 2.3427 Hp BreakDown Efficiency 51.1 %

Br eakDown Power Factor 72.005 BreakDown Input Power 3420.5 Watts Phase Current Density at BreakDown 6566.82 A/sq. in.

5A.6.10 Reactance Values

Primary Slot Leakage 0.9844 Ohms Secondary Slot Leakage 0.9893 Ohms End Leakage 0.5093 Ohms Skew Leakage 0.7003 Ohms Zig Zag Leakage 1.4209 Ohms Belt Leakage 0.2273 Ohms Primary Leakage Reactance 3.8422 Ohms Rotor Leakage 3.4006 Ohms Magnitizing Reactance 63.7112 Ohms

5A.6.11 Winding Information

Hot Rotor Resistance 2.4423 Ohms

Rotor Resistance Ratio 0.3372 Cold Winding Resistance 1.2508 Hot Winding Resistance 1.6262 Ohms Winding Distribution Factor 0.966 Total Winding Conductors per Phase 352.00 Conductors Effective Winding Conductors per Phase 340.0 Conductors

Slot 1 % Fill 62.88 %

Slot 2 % Fill 62.88 %5A-11

Slot 3 % Fill 0.00 %

Slot 4 % Fill 0.00 %

Slot 5 % Fill 0.00 %

Slot 6 % Fill 0.00 %

Slot 7 % Fill 0.00 %

Slot 8 % Fill 0.00 % Total Weight of the Copper 5.8887 lbs Electrical Area of One Rotor Bar 0.0261 sq. in. Electrical Area of All Rotor Bars 0.9386 sq. in. Weight of Stator Steel 15.9832 lbs Weight of Rotor Steel 7.2950 lbs Weight of Stator and Rotor Steel 23.2782 lbs Weight of Rotor Aluminum 0.6645 lbs

5A.6.12 Magnetic Circuit Data

Magnetic Length of Air Gap 0.0115 inch Total Air Gap Flux per Pole 287.1 kilolines Flux Density in Air Gap 49.4 Klines/in^2 Flux Density in Stator Yoke 90.9 Klines/in^2 Flux Density in Stator Teeth 80.2 Klines/in^2 Flux Density in Rotor Yoke 46.4 Klines/in^2 Flux Density in Rotor Teeth 101.3 Klines/in^2 MMF Drop in Air Gap 177.8 A-T MMF Drop in Stator Yoke 21.4 A-T MMF Drop in Rotor Yoke 0.7 A-T MMF Drop in Statot Teeth 5.3 A-T MMF Drop in Rotor Teeth 18.1 A-T Total MMF Drop 223.4 A-T5A-12

Figure 6.1 Torque and Output Power versus Speed for Efficiency Level 5, SpaceConstrained, Polyphase Motor

Figure 6.2 Current versus Speed for Efficiency Level 5, Space-Constrained, Polyphase

Motor5A-13

5A.7 DESIGN SPECIFICATIONS OF BASELINE CSIR MOTOR

5A.7.1 Stator Dimensions

Lamination Steel Type Tempel M56 Length of the Stator Stack 1.9780 inch Stacking Factor of the Stator 0.9800

Stator Slot Insulation Thickness 0.0100 inch

Number of Stator Poles 4 Poles

Outside Diameter of the Stator 5.8000 inch

Number of Stator Slots 32

Inside Diameter of the Stator 3.2524 inch Thickness of mid slot separator 0.0000 inch Stator Slot Width Next to Gap 0.1650 inch

Stator Slot Width at Bottom of Slot 0.2730 inch Depth of Main Trapezoidal Part 0.6980 inch Depth of Slot Mouth 0.0300 inch Stator Slot Opening 0.1000 inch Depth of Tooth Tip 0.0300 inch Total Depth of Stator Slot 0.7580 inch

5A.7.2 Rotor Dimensions

Shaft Material Magnetic

Outside Diameter of the Rotor 3.2292 inch

Inside Diameter of the Rotor 0.6250 inch Length of the Rotor Stack 2.0150 inch Stacking Factor of the Rotor 0.9800

5A.7.3 Rotor Slot Dimensions

Closed Bridge, Trap w/ Round Bottom Depth of Rotor Slot Opening 0.0000 inch Width at Top of Rotor Slot 0.1450 inch

Width at Bottom of Rotor Slot 0.0300 inch Depth of Main Trapezoidal Part 0.1650 inch Depth of Slot Mouth 0.0725 inch Depth of Bridge 0.0120 inch Total Depth of Rotor Slot 0.2650 inch

Number of Rotor Slots 44 slots

5A.7.4 Ring & Coil Data

Inside Diameter of Ring 1 2.0900 inch Outside Diameter of Ring 1 3.1070 inch Axial Thickness at Outside of Ring 1 0.1800 inch Axial Thickness at Inside of Ring 1 0.1800 inch Inside Diameter of Ring 2 2.0900 inch5A-14

Outside Diameter of Ring 2 3.1070 inch Axial Thickness at Outside of Ring 2 0.3900 inch Axial Thickness at Inside of Ring 2 0.3900 inch Conductivity of the Rotor Bar Material 0.5700 Conductivity of the End Ring Material 0.5700

5A.7.5 Electrical Data

Wire Insulation Type Heavy Terminal Voltage 115.00 Volts Turns per Coil in Main Slot 1 50 Turns Turns per Coil in Main Slot 2 42 Turns Turns per Coil in Main Slot 3 40 Turns Main Winding Wire Size 18.5 AWG Turns per Coil in Aux. Slot 1 58 Turns Turns per Coil in Aux. Slot 2 20 Turns Turns per Coil in Aux. Slot 3 15 Turns Auxiliary Wire Size 21.5 AWG Running Capacitance 0.0000 mfd Starting Capacitance 333.0000 mfd Line Frequency 60.0 Hz

Rotor Skew 2.00 bar Winding Operating Temperature 111.00 deg C Friction & Windage Loss at Idle Speed 14.0000 Watts Stray Load Loss 1.8 %

Wire Stretch Factor 1.040

5A.7.6 Load Speed & Slip Info

Specified Load Speed 1723.0 RPM Minimum Load Speed 0.0 RPM Speed Increment 10.0 RPM

5A.7.7 No Load Performance

Synchronous Speed 1800.0 RPM Actual No Load Speed 1792.8 RPM Actual No Load Line Current 8.02 Amps No Load Main Winding Current Density 3515.96 Amps/sq. in No Load Aux. Winding Current Density 0.00 Amps/sq. in

5A.7.8 Locked Rotor Data

Locked Rotor Torque 50.17 lb- in Locked Rotor Line Current 37.996 Amps Locked Rotor Main Current Density 13047.97 A/sq. in. Locked Rotor Aux. Current Density 18987.36 A/sq. in.5A-15

5A.7.9 Breakdown Load Parameters

BreakDown Speed 1396.8 RPM BreakDown Torque 46.20 lb- in BreakDown Current 19.83 Amps BreakDown Output Power 763.6 Watts BreakDown Output Power 1.0236 Hp BreakDown Efficiency 41.3 %

BreakDown Power Factor 0.792 BreakDown Input Power 1850.8 Watts Main Current Density at BreakDown 8697.58 A/sq. in. Aux. Current Density at BreakDown 0.00 A/sq. in.

5A.7.10 Reactance Values

Primary Slot Leakage 0.5834 Ohms Secondary Slot Leakage 0.3506 Ohms End Leakage 0.3500 Ohms Skew Leakage 0.6578 Ohms Zig Zag Leakage 0.7103 Ohms Belt Leakage 0.1465 Ohms Main Winding Leakage Reactance 1.6906 Ohms Rotor Leakage Referred to Main 1.1079 Ohms Auxiliary Winding Leakage Reactance 4.8096 Ohms Magnitizing Reactance of Main Winding 23.9646 Ohms

5A.7.11 Winding Information

Hot Rotor Resistance 1.5768 Ohms

Rotor Resistance Ratio 0.5634 Cold Auxiliary Resistance 5.3646 Ohms Cold Main Winding Resistance 0.8715 Hot Main Winding Resistance 1.1598 Ohms Hot Aux. Winding Resistance 7.1397 Ohms Main Winding Distribution Factor 0.804 Aux. Winding Distribution Factor 0.880 Total Main Winding Conductors 528.00 Conductors Total Aux. Winding Conductors 744.00 Conductors Effective Main Winding Conductors 424.7 Conductors Effective Aux. Winding Conductors 654.8 Conductors

Turns Ratio 1.54

Slot 1 % Fill 51.04 %

Slot 2 % Fill 50.78 %

Slot 3 % Fill 51.38 %

Slot 4 % Fill 30.59 %

Slot 5 % Fill 0.00 %

Slot 6 % Fill 0.00 %5A-16

Slot 7 % Fill 0.00 %

Slot 8 % Fill 0.00 % Total Weight of the Main Winding 2.2040 lbs Total Weight of the Aux. Winding 0.8428 lbs Electrical Area of One Rotor Bar 0.0250 sq. in. Electrical Area of All Rotor Bars 1.0978 sq. in. Weight of Stator Steel 6.7755 lbs Weight of Rotor Steel 3.9309 lbs Weight of Stator and Rotor Steel 10.7064 lbs Weight of Rotor Aluminum 0.4396 lbs

5A.7.12 Magnetic Circuit Data

Magnetic Length of Air Gap 0.0145 inch Total Air Gap Flux per Pole 197.0 kilolines Flux Density in Air Gap 52.3 Klines/in^2 Flux Density in Stator Yoke 93.6 Klines/in^2 Flux Density in Stator Teeth 113.5 Klines/in^2 Flux Density in Rotor Yoke 41.2 Klines/in^2 Flux Density in Rotor Teeth 117.7 Klines/in^2 MMF Drop in Air Gap 236.9 A-T MMF Drop in Stator Yoke 7.9 A-T MMF Drop in Rotor Yoke 1.0 A-T MMF Drop in Statot Teeth 66.1 A-T MMF Drop in Rotor Teeth 145.4 A-T Total MMF Drop 457.4 A-T

Figure 7.1 Torque and Output Power versus Speed for Baseline CSIR Motor5A-17 Figu re 7.2 Line Current versus Speed for Baseline CSIR Motor

5A.8 DESIGN SPECIFICATIONS OF CSIR TSL 7 (EL 7 SPACE CONSTRAINED)

DESIGN

5A.8.1 Stator Dimensions

Lamination Steel Type Hiperco 50A Length of the Stator Stack 2.4000 inch Stacking Factor of the Stator 0.9800

Stator Slot Insulation Thickness 0.0100 inch

Number of Stator Poles 4 Poles

Outside Diameter of the Stator 5.8000 inch

Number of Stator Slots 32

Inside Diameter of the Stator 3.2524 inch Thickness of mid slot separator 0.0000 inch Stator Slot Width Next to Gap 0.1650 inch

Stator Slot Width at Bottom of Slot 0.2730 inch Depth of Main Trapezoidal Part 0.6980 inch Depth of Slot Mouth 0.0300 inch Stator Slot Opening 0.1000 inch Depth of Tooth Tip 0.0300 inch Total Depth of Stator Slot 0.7580 inch

5A.8.2 Rotor Dimensions

Shaft Material Magnetic

Outside Diameter of the Rotor 3.2292 inch5A-18

Inside Diameter of the Rotor 0.6250 inch Length of the Rotor Stack 2.4000 inch Stacking Factor of the Rotor 0.9800 Slot Shape Closed Bridge, Trap w/ Round Bottom Depth of Rotor Slot Opening 0.0000 inch Width at Top of Rotor Slot 0.1450 inch

Width at Bottom of Rotor Slot 0.0300 inch Depth of Main Trapezoidal Part 0.1650 inch Depth of Slot Mouth 0.0725 inch Depth of Bridge 0.0120 inch Total Depth of Rotor Slot 0.2650 inch

Number of Rotor Slots 44 slots

5A.8.3 Ring & Coil Data

Inside Diameter of Ring 1 2.4000 inch Outside Diameter of Ring 1 3.1070 inch Axial Thickness at Outside of Ring 1 0.1500 inch Axial Thickness at Inside of Ring 1 0.1500 inch Inside Diameter of Ring 2 2.4000 inch Outside Diameter of Ring 2 3.1070 inch Axial Thickness at Outside of Ring 2 0.1500 inch Axial Thickness at Inside of Ring 2 0.1500 inch Conductivity of the Rotor Bar Material 1.0000 Conductivity of the End Ring Material 1.0000

5A.8.4 Electrical Data

Wire Insulation Type Heavy Terminal Voltage 115.00 Volts Turns per Coil in Main Slot 1 49 Turns Turns per Coil in Main Slot 2 46 Turns Turns per Coil in Main Slot 3 44 Turns Main Winding Wire Size 20.5 AWG Turns per Coil in Aux. Slot 1 49 Turns Turns per Coil in Aux. Slot 2 12 Turns Turns per Coil in Aux. Slot 3 8 Turns Auxiliary Wire Size 21.5 AWG Running Capacitance 0.0000 mfd Starting Capacitance 333.0000 mfd Line Frequency 60.0 Hz

Rotor Skew 2.00 bar Winding Operating Temperature 95.00 deg C Friction & Windage Loss at Idle Speed 14.0000 Watts Stray Load Loss 1.8 %

Wire Stretch Factor 1.0405A-19

5A.8.5 Load Speed & Slip Info

Specified Load Speed 1736.0 RPM Minimum Load Speed 0.0 RPM Speed Increment 10.0 RPM

5A.8.6 No Load Performance

Syn Synchronous Speed 1800.0 RPM Snl Actual No Load Speed 1796.4 RPM Inl Actual No Load Line Current 4.44 Amps GnlM No Load Main Winding Current Density 1539.14 Amps/sq. in GnlA No Load Aux. Winding Current Density 0.00 Amps/sq. in

5A.8.7 Locked Rotor Data

Locked Rotor Torque 51.60 lb-in Locked Rotor Line Current 32.111 Amps Locked Rotor Main Current Density 8483.25 A/sq. in. Locked Rotor Aux. Current Density 26619.81 A/sq. in.

5A.8.8 Breakdown Load Parameters

BreakDown Speed 1495.8 RPM BreakDown Torque 42.25 lb- in BreakDown Current 16.06 Amps BreakDown Output Power 748.0 Watts BreakDown Output Power 1.0027 Hp BreakDown Efficiency 53.9 %

BreakDown Power Factor 0.748 BreakDown Input Power 1387.6 Watts Main Current Density at BreakDown 5566.84 A/sq. in. Aux. Current Density at BreakDown 0.00 A/sq. in.

5A.8.9 Reactance Values

Primary Slot Leakage 0.7789 Ohms Secondary Slot Leakage 0.4542 Ohms End Leakage 0.3749 Ohms Skew Leakage 1.2435 Ohms Zig Zag Leakage 0.9375 Ohms Belt Leakage 0.2769 Ohms Main Winding Leakage Reactance 2.3827 Ohms Rotor Leakage Referred to Main 1.6832 Ohms Auxiliary Winding Leakage Reactance 3.9179 Ohms Magnitizing Reactance of Main Winding 45.2998 Ohms5A-20

5A.8.10 Winding Information

Hot Rotor Resistance 1.4990 Ohms

Rotor Resistance Ratio 0.3687 Cold Auxiliary Resistance 4.3866 inch Cold Main Winding Resistance 0.7775 Hot Main Winding Resistance 0.9870 Ohms Hot Aux. Winding Resistance 5.5681 Ohms Main Winding Distribution Factor 0.797 Aux. Winding Distribution Factor 0.906 Total Main Winding Conductors 556.00 Conductors Total Aux. Winding Conductors 552.00 Conductors Effective Main Winding Conductors 443.0 Conductors Effective Aux. Winding Conductors 499.8 Conductors

Turns Ratio 1.13

Slot 1 % Fill 64.73 %

Slot 2 % Fill 64.98 %

Slot 3 % Fill 64.45 %

Slot 4 % Fill 25.84 %

Slot 5 % Fill 0.00 %

Slot 6 % Fill 0.00 %

Slot 7 % Fill 0.00 %

Slot 8 % Fill 0.00 % Total Weight of the Main Winding 3.1463 lbs Total Weight of the Aux. Winding 0.6892 lbs Electrical Area of One Rotor Bar 0.0250 sq. in. Electrical Area of All Rotor Bars 1.0978 sq. in. Weight of Stator Steel 8.2211 lbs Weight of Rotor Steel 4.6819 lbs Weight of Stator and Rotor Steel 12.9030 lbs Weight of Rotor Aluminum 1.0858 lbs

5A.8.11 Magnetic Circuit Data

Magnetic Length of Air Gap 0.0145 inch Total Air Gap Flux per Pole 188.9 kilolines Flux Density in Air Gap 43.6 Klines/in^2 Flux Density in Stator Yoke 73.9 Klines/in^2 Flux Density in Stator Teeth 89.7 Klines/in^2 Flux Density in Rotor Yoke 34.6 Klines/in^2 Flux Density in Rotor Teeth 98.9 Klines/in^2 MMF Drop in Air Gap 197.3 A-T MMF Drop in Stator Yoke 2.0 A-T MMF Drop in Rotor Yoke 0.4 A-T MMF Drop in Statot Teeth 1.2 A-T MMF Drop in Rotor Teeth 0.5 A-T Total MMF Drop 201.3 A-T5A-21

5A.8.12 Overall Cost and Pricing Data

Number of Laminations 392 Price per Lamination $0.0000 / Lams Total Cost of the Lamination $0.0000 Total Cost of Rotor Shell Material $0.0000 Total Cost of the Shaft Material $0.0000 Weight of the Copper Wiring 3.8355 lbs. Price per Pound of Copper $0.0000 / lb Total Copper Cost $0.0000 Weight of the Rotor Aluminu m 1.0858 lbs. Price per Pound of Aluminum $0.0000 / lb Total Aluminum Cost $0.0000 Cost for Bearing in End Frame 1 $0.0000 Cost for Bearing in End Frame 2 $0.0000 Total Material Cost $0.0000

Figure 8.1 Torque and Output Power versus Speed for Efficiency Level 7, SpaceConstrained, CSIR Motor5A-22

Figure 8.2 Line Current versus Speed for Efficiency Level 7, Space-Constrained, CSIR

Motor

5A.9 DESIGN SPECIFICATIONS OF BASELINE CSCR MOTOR

5A.9.1 Stator Dimensions

Lamination Steel Type Tempel M56 Length of the Stator Stack 3.0000 inch Stacking Factor of the Stator 0.9800

Stator Slot Insulation Thickness 0.0100 inch

Number of Stator Poles 4 Poles

Outside Diameter of the Stator 5.5000 inch

Number of Stator Slots 32

Inside Diameter of the Stator 3.3750 inch Thickness of mid slot separator 0.0000 inch Stator Slot Width Next to Gap 0.1650 inch

Stator Slot Width at Bottom of Slo t 0.2730 inch Depth of Main Trapezoidal Part 0.6500 inch Depth of Slot Mouth 0.0300 inch Stator Slot Opening 0.1000 inch Depth of Tooth Tip 0.0300 inch Total Depth of Stator Slot 0.7100 inch

5A.9.2 Rotor Dimensions

Shaft Material Ma gnetic

Outside Diameter of the Rotor 3.3500 inch

Inside Diameter of the Rotor 0.6250 inch5A-23

Length of the Rotor Stack 3.0000 inch Stacking Factor of the Rotor 0.9800

5A.9.3 Rotor Slot Dimensions

Closed Bridge, Trap w/ Round Bottom Depth of Rotor Slot Opening 0.0000 inch Width at Top of Rotor Slot 0.1360 inch

Width at Bottom of Rotor Slot 0.0300 inch Depth of Main Trapezoidal Part 0.2200 inch Depth of Slot Mouth 0.0680 inch Depth of Bridge 0.0070 inch Total Depth of Rotor Slot 0.3200 inch

Number of Rotor Slots 40 slots

5A.9.4 Ring & Coil Data

Inside Diameter of Ring 1 2.1500 inch Outside Diameter of Ring 1 3.2250 inch Axial Thickness at Outside of Ring 1 0.3900 inch Axial Thickness at Inside of Ring 1 0.3900 inch

In side Diameter of Ring 2 2.1500 inch Outside Diameter of Ring 2 3.2250 inch Axial Thickness at Outside of Ring 2 0.3900 inch Axial Thickness at Inside of Ring 2 0.3900 inch Conductivity of the Rotor Bar Material 0.5700 Conductivity of the End Ring Material 0.5700

5A.9.5 Electrical Data

Wire Insulation Type Heavy Terminal Voltage 115.00 Volts Turns per Coil in Main Slot 1 45 Turns Turns per Coil in Main Slot 2 33 Turns Turns per Coil in Main Slot 3 20 Turns Main Winding Wire Size 18.0 AWG Turns per Coil in Aux. Slot 1 42 Turns Turns per Coil in Aux. Slot 2 25 Turns Turns per Coil in Aux. Slot 3 10 Turns Auxiliary Wire Size 19.0 AWG Running Capacitance 7.5700 mfd Starting Capacitance 433.0000 mfd Line Frequency 60.0 Hz

Rotor Skew 1.60 bar Winding Operating Temperature 67.00 deg C Friction & Windage Loss at Idle Speed 5.0000 Watts Stray Load Loss 1.8 %5A-24

Wire Stretch Factor 1.040

5A.9.6 Load Speed & Slip Info

Specified Load Speed 1735.0 RPM Minimum Load Speed 0.0 RPM Speed Increment 10.0 RPM

5A.9.7 No Load Performance

Synchronous Speed 1800.0 RPM Actual No Load Speed 1798.2 RPM Actual No Load Line Current 7.20 Amps No Load Main Winding Current Density 2927.14 Amps/sq. in No Load Aux. Winding Current Density 489.66 Amps/sq. in

5A.9.8 Locked Rotor Data

Locked Rotor Torque 76.42 lb- in Locked Rotor Line Current 53.173 Amps Locked Rotor Main Current Density 14837.96 A/sq. in. Locked Rotor Aux. Current Density 19147.49 A/sq. in.

5A.9.9 Breakdown Load Parameters

BreakDown Speed 1476.0 RPM BreakDown Torque 63.47 lb- in BreakDown Current 24.80 Amps BreakDown Output Power 1108.6 Watts BreakDown Output Power 1.4861 Hp BreakDown Efficiency 49.9 %

BreakDown Power Factor 0.780 BreakDown Input Power 2223.3 Watts Main Current Density at BreakDown 9591.20 A/sq. in. Aux. Current Density at BreakDown 200.63 A/sq. in.

5A.9.10 Reactance Values

Primary Slot Leakage 0.5069 Ohms Secondary Slot Leakage 0.3891 Ohms End Leakage 0.2312 Ohms Skew Leakage 0.5159 Ohms Zig Zag Leakage 0.6773 Ohms Belt Leakage 0.1535 Ohms Main Winding Leakage Reactance 1.4115 Ohms Rotor Leakage Referred to Main 1.0625 Ohms Auxiliary Winding Leakage Reactance 4.0702 Ohms5A-25

Magnitizing Reactance of Main Winding 24.3242 Ohms

5A.9.11 Winding Information

Hot Rotor Resistance 1.0292 Ohms

Rotor Resistance Ratio 0.4160 Cold Auxiliary Resistance 2.8797 inch Cold Main Winding Resistance 0.7054 Hot Main Winding Resistance 0.8194 Ohms R1A Hot Aux. Winding Resistance 3.3450 Ohms Main Winding Distribution Factor 0.844 Aux. Winding Distribution Factor 0.877 Total Main Winding Conductors 392.00 Conductors Total Aux. Winding Conductors 616.00 Conductors Effective Main Winding Conductors 330.7 Conductors Effective Aux. Winding Conductors 540.3 Conductors

Turns Ratio 1.63

Slot 1 % Fill 54.17 %

Slot 2 % Fill 49.38 %

Slot 3 % Fill 48.21 %

Slot 4 % Fill 40.55 %

Slot 5 % Fill 0.00 %

Slot 6 % Fill 0.00 %

Slot 7 % Fill 0.00 %

Slot 8 % Fill 0.00 % Total Weight of the Main Winding 2.2330 lbs Total Weight of the Aux. Winding 1.4352 lbs Electrical Area of One Rotor Bar 0.0275 sq. in. Electrical Area of All Rotor Bars 1.1003 sq. in. Weight of Stator Steel 7.7508 lbs Weight of Rotor Steel 6.3664 lbs Weight of Stator and Rotor Steel 14.1171 lbs Weight of Rotor Aluminum 0.6625 lbs

5A.9.12 Magnetic Circuit Data

Magnetic Length of Air Gap 0.0154 inch Total Air Gap Flux per Pole 253.0 kilolines Flux Density in Air Gap 45.0 Klines/in^2 Flux Density in Stator Yoke 113.3 Klines/in^2 Flux Density in Stator Teeth 91.5 Klines/in^2 Flux Density in Rotor Yoke 36.9 Klines/in^2 Flux Density in Rotor Teeth 87.1 Klines/in^2 MMF Drop in Air Gap 216.2 A-T MMF Drop in Stator Yoke 119.6 A-T MMF Drop in Rotor Yoke 0.9 A-T MMF Drop in Statot Teeth 3.5 A-T5A-26

MMF Drop in Rotor Teeth 1.4 A-T Total MMF Drop 341.6 A-T

Figure 9.1 Torque and Output Power versus Speed for Baseline CSCR Motor

Figure 9.2 Line Current versus Speed for Baseline CSCR Motor5A-27

5A.10 DESIGN SPECIFICATIONS OF CSCR TSL 7 (EL 3 SPACE CONSTRAINED)

DESIGN

5A.10.1 Stator Dimensions

Lamination Steel Type M 19 Length of the Stator Stack 3.4500 inch Stacking Factor of the Stator 0.9800

Stator Slot Insulation Thickness 0.0100 inch

Number of Stator Poles 4 Poles

Outside Diameter of the Stator 5.5000 inch

Number of Stator Slots 32

Inside Diameter of the Stator 3.3750 inch Thickness of mid slot separator 0.0000 inch Stator Slot Width Next to Gap 0.1650 inch

Stator Slot Width at Bottom of Slot 0.2730 inch Depth of Main Trapezoidal Part 0.6500 inch Depth of Slot Mouth 0.0300 inch Stator Slot Opening 0.1000 inch Depth of Tooth Tip 0.0300 inch Total Depth of Stator Slot 0.7100 inch

5A.10.2 Rotor Dimensions

Shaft Material Magnetic

Outside Diameter of the Rotor 3.3500 inch

Inside Diameter of the Rotor 0.6250 inch Length of the Rotor Stack 3.4500 inch Stacking Factor of the Rotor 0.9800

5A.10.3 Rotor Slot Dimensions

Closed Bridge, Trap w/ Round Bottom Depth of Rotor Slot Opening 0.0000 inch Width at Top of Rotor Slot 0.1360 inch

Width at Bottom of Rotor Slot 0.0300 inch Depth of Main Trapezoidal Part 0.2200 inch Depth of Slot Mouth 0.0680 inch Depth of Bridge 0.0070 inch Total Depth of Rotor Slot 0.3200 inch

Number of Rotor Slots 40 slots

5A.10.4 Ring & Coil Data

Inside Diameter of Ring 1 2.1500 inch Outside Diameter of Ring 1 3.2250 inch Axial Thickness at Outside of Ring 1 0.3900 inch Axial Thickness at Inside of Ring 1 0.3900 inch5A-28

Inside Diameter of Ring 2 2.1500 inch Outside Diameter of Ring 2 3.2250 inch Axial Thickness at Outside of Ring 2 0.3900 inch Axial Thickness at Inside of Ring 2 0.3900 inch Conductivity of the Rotor Bar Material 0.5700 Conductivity of the End Ring Material 0.5700

5A.10.5 Electrical Data

Wire Insulation Type Heavy Terminal Voltage 115.00 Volts Turns per Coil in Main Slot 1 40 Turns Turns per Coil in Main Slot 2 34 Turns Turns per Coil in Main Slot 3 23 Turns Main Winding Wire Size 20.0 AWG Turns per Coil in Aux. Slot 1 42 Turns Turns per Coil in Aux. Slot 2 23 Turns Turns per Coil in Aux. Slot 3 7 Turns Auxiliary Wire Size 21.0 AWG Running Capacitance 25.0000 mfd Starting Capacitance 433.0000 mfd Line Frequency 60.0 Hz

Rotor Skew 1.60 bar Winding Operating Temperature 67.00 deg C Friction & Windage Loss at Idle Speed 5.0000 Watts Stray Load Loss 1.8 %

Wire Stretch Factor 1.040

5A.10.6 Load Speed & Slip Info

Specified Load Speed 1742.0 RPM Minimum Load Speed 0.0 RPM Speed Increment 10.0 RPM

5A.10.7 No Load Performance

Synchronous Speed 1800.0 RPM Actual No Load Speed 1798.2 RPM Actual No Load Line Current 4.22 Amps No Load Main Winding Current Density 1689.71 Amps/sq. in No Load Aux. Winding Current Density 1580.81 Amps/sq. in

5A.10.8 Locked Rotor Data

Locked Rotor Torque 81.11 lb- in Locked Rotor Line Current 54.293 Amps Locked Rotor Main Current Density 11449.70 A/sq. in. Locked Rotor Aux. Current Density 16725.67 A/sq. in.5A-29

5A.10.9 Breakdown Load Parameters

BreakDown Speed 1479.6 RPM BreakDown Torque 69.43 lb- in BreakDown Current 23.60 Amps BreakDown Output Power 1215.8 Watts BreakDown Output Power 1.6297 Hp BreakDown Efficiency 56.2 %

BreakDown Power Factor 0.797 BreakDown Input Power 2163.4 Watts Main Current Density at BreakDown 7190.63 A/sq. in. Aux. Current Density at BreakDown 815.32 A/sq. in.

5A.10.10 Reactance Values

Primary Slot Leakage 0.5450 Ohms Secondary Slot Leakage 0.4218 Ohms End Leakage 0.2116 Ohms Skew Leakage 0.5593 Ohms Zig Zag Leakage 0.7343 Ohms Belt Leakage 0.1664 Ohms Main Winding Leakage Reactance 1.4865 Ohms Rotor Leakage Referred to Main 1.1518 Ohms Auxiliary Winding Leakage Reactance 4.4157 Ohms Magnitizing Reactance of Main Winding 26.3688 Ohms

5A.10.11 Winding Information

Hot Rotor Resistance 1.0890 Ohms

Rotor Resistance Ratio 0.4127 Cold Auxiliary Resistance 2.3109 inch Cold Main Winding Resistance 0.5843 Hot Main Winding Resistance 0.6788 Ohms Hot Aux. Winding Resistance 2.6843 Ohms Main Winding Distribution Factor 0.828 Aux. Winding Distribution Factor 0.892 Total Main Winding Conductors 388.00 Conductors Total Aux. Winding Conductors 576.00 Conductors Effective Main Winding Conductors 321.1 Conductors Effective Aux. Winding Conductors 513.6 Conductors

Turns Ratio 1.60

Slot 1 % Fill 62.06 %

Slot 2 % Fill 61.41 %

Slot 3 % Fill 64.14 %

Slot 4 % Fill 51.97 %

Slot 5 % Fill 0.00 %

Slot 6 % Fill 0.00 %5A-30

Slot 7 % Fill 0.00 %

Slot 8 % Fill 0.00 % Total Weight of the Main Winding 2.9416 lbs Total Weight of the Aux. Winding 1.8298 lbs Electrical Area of One Rotor Bar 0.0275 sq. in. Electrical Area of All Rotor Bars 1.1003 sq. in. Weight of Stator Steel 8.9134 lbs Weight of Rotor Steel 7.3213 lbs Weight of Stator and Rotor Steel 16.2347 lbs Weight of Rotor Aluminum 0.7089 lbs

5A.10.12 Magnetic Circuit Data

Magnetic Length of Air Gap 0.0154 inch Total Air Gap Flux per Pole 260.5 kilolines Flux Density in Air Gap 40.5 Klines/in^2 Flux Density in Stator Yoke 101.4 Klines/in^2 Flux Density in Stator Teeth 81.9 Klines/in^2 Flux Density in Rotor Yoke 33.2 Klines/in^2 Flux Density in Rotor Teeth 78.4 Klines/in^2 MMF Drop in Air Gap 194.6 A-T MMF Drop in Stator Yoke 96.7 A-T MMF Drop in Rotor Yoke 0.5 A-T MMF Drop in Statot Teeth 5.5 A-T MMF Drop in Rotor Teeth 2.2 A-T Total MMF Drop 299.4 A-T

Figure 10.1 Torque and Output Power versus Speed for Efficiency Level 3, SpaceConstrained, CSCR Motor5A-31

Figure 10.2 Line Current versus Speed for Efficiency Level 3, Space-Constrained, CSCR

Motor

5A.11 COMMODITY PRICES

Commodities such as steel, copper, and aluminum make up a large portion of the input materials to small electric motors. As a result, any fluctuation in the price of these commodities can have a significant impact on the cost to produce these motors. Over the past several years, these commodity prices have fluctuated greatly compared to their historical trends. In an effort to best estimate the price of these underlying commodities, DOE has used an inflation adjusted five-year average price point for these commodities throughout the Engineering Analysis. In calculating the five-year average prices, DOE adjusted historical prices to $2008 using the historical Bureau of Labor Statistics Producer Price Indices (PPI) 1 for each commodity’s industry. Table 11.1 summarizes the historical five-year prices in terms of 2008$, and also shows the average price point DOE used for its analysis.5A-32

Table 11.1 Five-Year Commodity Prices in 2008$

Commodity Unit of

Measure 2008 2007 2006 2005 2004 5

- Year Average Copper Wire Gauge 18.0 $/lb $3.06 $2.58 $2.50 $2.39 $2.29 $2.56 Gauge 18.5 $/lb $3.07 $2.59 $2.51 $2.40 $2.30 $2.57 Gauge 19.0 $/lb $3.08 $2.60 $2.51 $2.41 $2.31 $2.58 Gauge 19.5 $/lb $3.09 $2.61 $2.52 $2.42 $2.32 $2.59 Gauge 20.0 $/lb $3.10 $2.62 $2.53 $2.43 $2.33 $2.60 Gauge 20.5 $/lb $3.11 $2.63 $2.54 $2.44 $2.33 $2.61 Gauge 21.0 $/lb $3.12 $2.64 $2.55 $2 .45 $2.34 $2.62 Gauge 21.5 $/lb $3.13 $2.65 $2.56 $2.46 $2.35 $2.63 Gauge 22.0 $/lb $3.15 $2.66 $2.57 $2.46 $2.36 $2.64 Casting Materials Copper $/lb $2.02 $2.05 $1.90 $1.13 $0.96 $1.61

Aluminum $/lb $0.65 $0.62 $0.61 $0.57 $0.56 $0.60

Core St eel

24M56 $/lam $0.14 $0.16 $0.13 $0.11 $0.10 $0.13

24M19 $/lam $0.23 $0.26 $0.22 $0.18 $0.16 $0.21

29M15 $/lam $0.36 $0.40 $0.34 $0.28 $0.25 $0.32 Hiperco 50 $/lam $1.77 $1.96 $1.67 $1.38 $1.21 $1.60

DOE based its Engineering Analysis on the five-year average price point for each commodity, but it also examined the five-year minimum and maximum price points to gauge the level of sensitivity around these prices. Table 11.2 to Table 11.7 present the resulting MSPs from using the five-year average price, the minimum price, and the maximum price for polyphase, CSIR, and CSCR motors. Figure 11.1 through Figure 11.6 show the MSP-efficiency graphs associated with these values.5A-33

Table 11.2 Commodity Price Impact on MSP for Space Constrained Polyphase Motors

Efficiency Level (%) Minimum Prices

(2008$) Five

- Year Average

Prices (2008$) Maximum Prices (2 008$)

Baseline 77. 2 89.58 97.74 106.66

EL 1 78.7 94.81 103.81 113.87

EL 2 80 .0 97.26 107.01 117.99

EL 3 81.6 102.61 112.88 124.65

EL 4 82.5 106.20 117.01 129.55

EL 5 85.2 191.47 229.84 267.81

EL 6 86.7 196.09 236.20 275.44

EL 7 88.3 1,356.72 1,770. 27 2,154.73

Figure 11.1 Commodity Price Impact on MSP for Space Constrained Polyphase Motors5A-34

Table 11.3 Commodity Price Impact on MSP for Non-Space Constrained Polyphase

Motors* Efficiency

Level (%) MSP From Min

.

Prices (2008$) MSP From Five

- Year

Avg. Prices (2008$) MSP From Max

. Prices (2008$)

EL 5 85.2 132.29 150.86 170.67

EL 6 86.4 159.55 184.73 211.26

EL 7 88.4 264.33 324.66 382.93
* Designs where the non-space constrained specifications are the same as the space constrained specifications have been omitted from this table. Since the specifications are the same, the resulting MSPs are the same. See the Table

11 .2 for detail on these designs.

Figure 11.2 Commodity Price Impact on MSP for Non-Space Constrained Polyphase

Motors5A-35

Table 11.4 Commodity Price Impact on MSP for Space Constrained CSIR Motors

Efficiency Level (%) Minimum Prices

(2008$) Five

- Year Average

Prices (2008$) Maximum Prices (2008$)

Baseline 57.7 85.61 91.04 97.34

EL 1 59.5 89.36 95.62 102.86

EL 2 62 .0 91.86 98.54 106.33

EL 3 64.2 92.87 99 .78 107.81

EL 4 68.5 104.11 114.57 125.88

EL 5 71.2 107.20 118.98 131.11

EL 6 73 .0 155.22 182.28 208.62

EL 7 77 .0 928.43 1,204.30 1,460.64

Figure 11.3 Commodity Price Impact on MSP for Space Constrained CSIR Motors5A-36

Table 11.5 Commodity Price Impact on MSP for Non-Space Constrained CSIR Motors*

Efficiency Level (%) MSP From Min.

Prices (2008$) MSP From Five

- Year

Avg. Prices (2008$) MSP From Max.

Prices (2008$)

EL 4 68.6 98.87 107.19 116.60

EL 5 71.2 109.42 120.53 132.86

EL 6 73.1 118.24 132.16 146.94

EL 7 77.2 132.21 150.70 169.28
* Designs where the non-space constrained specifications are the same as the space constrained specifications have been omitted from this table. Since the specifications are the same, the resulting MSPs are the same. See Table 11 .4 for detail on these designs.

Figure 11.4 Commodity Price Impact on MSP for Non-Space Constrained CSIR Motors5A-37

Table 11.6 Commodity Price Impact on MSP for Space Constrained CSCR Motors

Efficiency Level (%) Minimum Prices

(2008$) Five

- Year Average

Prices (2008$) Maximum Prices (2008$)

Baseline 71 .0 102.47 110.82 120.09

EL 1 74.3 107.07 116.06 126.18

EL 2 78.3 122.36 136.22 150.83

EL 3 80.3 126.82 141.49 157.09

EL 4 81.6 129.99 145.27 161.50

EL 5 82.7 134.98 152.88 170.80

EL 6 83.7 199.62 237.53 274 .53

EL 7 85.4 204.74 245.36 284.11

EL 8 87.3 1,364.52 1,778.48 2,162.34

Figure 11.5 Commodity Price Impact on MSP for Space Constrained CSCR Motors5A-38

Table 11.7 Commodity Price Impact on MSP for Non-Space Constrained CSCR Motors*

Efficiency Level (%) MSP From Min.

Prices (2008$) MSP From Five

- Year

Avg. Prices (2008$) MSP From Max. Prices (2008$)

EL 2 78.4 117.27 128.60 141.12

EL 3 80.5 121.34 133.71 147 .14

EL 4 81.8 126.69 141.10 156.01

EL 5 82.9 132.92 149.23 165.80

EL 6 83.5 139.06 156.85 174.89

EL 7 85.6 150.71 172.75 194.64

EL 8 87.3 288.18 353.50 415.59
* Designs where the non-space constrained specifications are the same as the space constrained specifications have been omitted from this table. Since the specifications are the same, the resulting MSPs are the same. See Table 11 .6 for detail on these designs.

Figure 11.6 Commodity Price Impact on MSP for Non-Space Constrained CSCR Motors

5A.12 SCALING RELATIONSHIPS

As part of the scaling process, DOE used listed catalog efficiency data from various manufacturers and test results performed by its subcontractor. The test results came from an independently accredited laboratory that tested the motors according to the applicable IEEE testprocedures: IEEE 112 (test methods A and B) for polyphase motors and IEEE 114 for singlephase motors. Table 12.1 and Table 12.2 show the efficiency data collected through these test procedures for polyphase and CSIR motors. As noted in chapter 5 of the TSD, no manufacturer offered a complete product line of CSCR motors, and therefore their scaling relationships were based upon the CSIR data.5A-39

Table 12.1 Test Results for Polyphase Motors
Horsepower/Standard Kilowatt Equivalent Six Poles
Efficiency (%) Four Poles

Efficiency (%) Two Poles

Efficiency (%)
1/4 hp/0.18 kW

1/3 hp/0.25 kW 65.3 61.3 54.9
1/2 hp/0.37 kW

3/4 hp/0.55 kW 71.8 65.7 1 hp/0.75 kW 74.0 68. 3 11⁄2 hp/1.1 kW

2 hp/1.5 kW 75. 7 78.8 ≥ 3 hp/2.2 kW

Table 12.2 Test Results for CSIR Motors
Horsepower/Standard Kilowatt Equivalent Six Poles
Efficiency (%) Four Poles

Efficiency (%) Two Poles

Efficiency (%)
1/4 hp/0.18 kW

1/3 hp/0.25 k W 47.7 51.4
1/2 hp/0.37 kW 64.2
3/4 hp/0.55 kW 66.5 55.3
1 hp/0.75 kW 75.7 67.7
11⁄2 hp/1.1 kW

2 hp/1.5 kW 81.9 67.4
≥ 3 hp/2.2 kW

Once the baseline efficiency levels were determined for product classes that were directly analyzed, DOE used its scaling tool to determine the appropriate efficiency levels for the remaining product classes. Table 12.3 through Table 12.5 show the scaled efficiency levels for each product class at the baseline efficiency level.5A-40

Table 12.3 Scaled Efficiency Levels for Baseline Polyphase Small Electric Motors
Horsepower/Standard Kilowatt Equivalent Six Poles
Efficiency (%) Four Poles

Efficiency (%) Two Poles

Effi ciency (%)
1/4 hp/0.18 kW 66.7 61.0 57.6 1/3 hp/0.25 kW 68.9 64.5 62.2 1/2 hp/0.37 kW 71.6 70.3 65.0 3/4 hp/0.55 kW 75.4 74.8 72.3 1 hp/0.75 kW 75.8 77.2 74.9 11⁄2 hp/1.1 kW 77.1 79.9 79.1 2 hp/1.5 kW 82.9 81.1 81.5 ≥ 3 hp/2.2 kW 85.2 84.0 84.8

Table 12.4 Scaled Efficiency Levels for Baseline CSIR Small Electric Motors
Horsepower/Standard Kilowatt Equivalent Six Poles
Efficiency (%) Four Poles

Efficiency (%) Two Poles

Efficiency (%)
1/4 hp/0.18 kW 43. 6 48.4 50.5 1/3 hp/0.25 kW 49.5 52.2 54.0 1/2 hp/0.37 kW 57.7 57.7 56.8 3/4 hp/0.55 kW 63.4 63.4 59.2 1 hp/0.75 kW 68.3 66.3 62.0 11⁄2 hp/1.1 kW 74.4 70.6 65.4 2 hp/1.5 kW 78.2 72.3 69.7 ≥ 3 hp/2.2 kW 82.7 76.5 70.7

Table 12.5 Scaled Efficiency Levels for Baseline CSCR Small Electric Motors
Horsepower/Standard Kilowatt Equivalent Six Poles
Efficiency (%) Four Poles

Efficiency (%) Two Poles

Efficiency (%)
1/4 hp/0.18 kW 51.5 56.4 58.4 1/3 hp/0.25 kW 57.5 60.3 61.8 1/2 hp/0.37 kW 65.3 65.5 64.4 3/4 hp/0.55 kW 70.5 71.0 66.7 1 hp/0.75 kW 74.8 73.3 69.3 11⁄2 hp/1.1 kW 80.0 77.1 72.4 2 hp/1.5 kW 83.1 78.8 76.1 ≥ 3 hp/2.2 kW 86.8 82.2 77.15A-41 REFERENCES

1 U.S. Department of Labor, Bureau of Labor Statistics, Producer Price Indices. Last accessed April 12, 2009. <http://www.bls.gov/ppi>.