APPENDIX 5A. ENGINEERING DATA 

TABLE OF CONTENTS 

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

5A.2	 BASELINE DESIGN OPTIONS........................................................................................ 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 ................................................................................................ 15
 

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EERE-2007-BT-STD-0007 COMMENT 17
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 ......................................................................................... 38
 

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EERE-2007-BT-STD-0007 COMMENT 17
 

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, 

Polyphase 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 Motor22
 

Figure 10.1 Torque and Output Power versus Speed for Efficiency Level 3, Space-Constrained, 

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
 

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

..................................................................................................................................... 31
 

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

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 ....... 38
 

5A-iii 

EERE-2007-BT-STD-0007 COMMENT 17
 

 

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 20.6 

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. The following list presents the entire list of design limitations: 

5A.4 COST-EFFICIENCY RELATIONSHIP VERIFICATION 

Once the cost-efficiency relationships were determined using the subcontractor’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 results 

5A-1 

EERE-2007-BT-STD-0007 COMMENT 17
$75

$95

$115

$135

$155

$175

$195

Manufacturer Selling Price (

55 60 65 70 75 80

$2008)

Full Load Efficiency (%)

Space Constrained

Non-Space Constrained

Tested Motors

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 Results 

5A-2 

EERE-2007-BT-STD-0007 COMMENT 17
$75

$125

$175

$225

$275

$325

$375

Manufacturer Selling Price (

70 75 80 85 90

$2008)

Full Load Efficiency (%)

Space Constrained

Non-Space 

Constrained

Tested Motors

$0

$50

$100

$150

$200

$250

$300

$350

Manufacturer Selling Price (

73 78 83 88 93

$2008)

Full Load Efficiency (%)

Space Constrained

Non-Space 

Constrained

Tested Motors

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 classes. This confirms that DOE’s cost-efficiency curves are sufficient in 

5A-3 

EERE-2007-BT-STD-0007 COMMENT 17
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 inch 

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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. 

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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 lbs 

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EERE-2007-BT-STD-0007 COMMENT 17
 

 

 

 

 

 

 

 

 

 

 

 

 

 

0

0.5

1

1.5

2

2.5

3

0%

50%

100%

150%

200%

250%

300%

350%

0% 20% 40% 60% 80% 100% 120%

Output Power (HP)

Torque (% of rated)

Speed (% of rated)

Torque

Power

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 Motor 

5A-7 

EERE-2007-BT-STD-0007 COMMENT 17
0

2

4

6

8

10

12

14

16

18

0% 20% 40% 60% 80% 100% 120%

Current (Amperes)

Speed (% of rated)

Current

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 inch 

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Inside Diameter of the Rotor 

Length of the Rotor Stack 

Stacking Factor of the Rotor 

5A.6.3 Rotor Slot Dimensions 

Closed Bridge, Trap w/ Round Bottom 

Depth of Rotor Slot Opening 

Width at Top of Rotor Slot 

Width at Bottom of Rotor Slot 

Depth of Main Trapezoidal Part 

Depth of Slot Mouth 

Depth of Bridge

Total Depth of Rotor Slot 

Number of Rotor Slots 

5A.6.4 Ring & Coil Data 

Inside Diameter of Ring 1 

Outside Diameter of Ring 1 

Axial Thickness at Outside of Ring 1 

Axial Thickness at Inside of Ring 1 

Inside Diameter of Ring 2 

Outside Diameter of Ring 2 

Axial Thickness at Outside of Ring 2 

Axial Thickness at Inside of Ring 2 

Conductivity of the Rotor Bar Material 

Conductivity of the End Ring Material 

5A.6.5 Electrical Data 

Wire Insulation Type 

Terminal Voltage

Turns per Coil in Slot 1 

Turns per Coil in Slot 2 

Winding Wire Size

Line Frequency

Rotor Skew 

Winding Operating Temperature 

Friction & Windage Loss at Idle Speed 

Stray Load Loss 

Wire Stretch Factor 

5A.6.6 Load Speed & Slip Info 

Specified Load Speed 

Minimum Load Speed 

Speed Increment 

0.9350 inch 

3.6000 inch 

0.9800 

0.0000 inch 

0.1400 inch 

0.0700 inch 

0.1750 inch 

0.0100 inch 

 0.0000 inch 

0.2750 inch 

36 slots 

2.2000 inch 

2.9400 inch 

0.5500 inch 

0.5500 inch 

2.2000 inch 

2.9400 inch 

0.5500 inch 

0.5500 inch 

0.5700 

0.5700 

 Heavy 

230.00 Volts 

44 Turns 

44 Turns 

19.5 AWG 

60.0 Hz 

1.50 bars 

103.00 deg C 

4.1790 Watts 

2.4 % 

1.030 

 1719.0 RPM 

0.0 RPM 

10.0 RPM 

5A-9 

EERE-2007-BT-STD-0007 COMMENT 17
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 % 

BreakDown 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 % 

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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-T 

5A-11 

EERE-2007-BT-STD-0007 COMMENT 17
0

0.5

1

1.5

2

2.5

3

0%

50%

100%

150%

200%

250%

300%

350%

0% 20% 40% 60% 80% 100% 120%

Output Power (HP)

Torque (% of rated)

Speed (% of rated)

Torque

Power

0

2

4

6

8

10

12

14

16

18

0% 20% 40% 60% 80% 100% 120%

Current (Amperes)

Speed (% of rated)

Current

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 

Motor 

5A-12 

EERE-2007-BT-STD-0007 COMMENT 17
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5A.7 DESIGN SPECIFICATIONS OF BASELINE CSIR MOTOR 

5A.7.1 Stator Dimensions 

Lamination Steel Type 

Length of the Stator Stack 

Stacking Factor of the Stator 

Stator Slot Insulation Thickness 

Number of Stator Poles 

Outside Diameter of the Stator 

Number of Stator Slots 

Inside Diameter of the Stator 

Thickness of mid slot separator 

Stator Slot Width Next to Gap 

Stator Slot Width at Bottom of Slot 

Depth of Main Trapezoidal Part 

Depth of Slot Mouth 

Stator Slot Opening

Depth of Tooth Tip 

Total Depth of Stator Slot 

5A.7.2 Rotor Dimensions 

Shaft Material

Outside Diameter of the Rotor 

Inside Diameter of the Rotor 

Length of the Rotor Stack 

Stacking Factor of the Rotor 

5A.7.3 Rotor Slot Dimensions 

Closed Bridge, Trap w/ Round Bottom 

Depth of Rotor Slot Opening 

Width at Top of Rotor Slot 

Width at Bottom of Rotor Slot 

Depth of Main Trapezoidal Part 

Depth of Slot Mouth 

Depth of Bridge

Total Depth of Rotor Slot 

Number of Rotor Slots 

5A.7.4 Ring & Coil Data 

Inside Diameter of Ring 1 

Outside Diameter of Ring 1 

Axial Thickness at Outside of Ring 1 

Axial Thickness at Inside of Ring 1 

Inside Diameter of Ring 2 

 Tempel M56 

1.9780 inch 

0.9800 

0.0100 inch 

4 Poles 

5.8000 inch 

32 

3.2524 inch 

0.0000 inch 

0.1650 inch 

0.2730 inch 

0.6980 inch 

0.0300 inch 

 0.1000 inch 

0.0300 inch 

0.7580 inch 

 Magnetic 

3.2292 inch 

0.6250 inch 

2.0150 inch 

0.9800 

0.0000 inch 

0.1450 inch 

0.0300 inch 

0.1650 inch 

0.0725 inch 

 0.0120 inch 

0.2650 inch 

44 slots 

2.0900 inch 

3.1070 inch 

0.1800 inch 

0.1800 inch 

2.0900 inch 

5A-13 

EERE-2007-BT-STD-0007 COMMENT 17
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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-14 

EERE-2007-BT-STD-0007 COMMENT 17
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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-15 

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Output Power (HP)

Torque (% of rated)

Speed (% of rated)

Torque

Power

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 Motor 

5A-16 

EERE-2007-BT-STD-0007 COMMENT 17
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Current (Amperes)

Speed (% of rated)

L Current

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 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 inch 

5A-17 

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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 1.040 

5A-18 

EERE-2007-BT-STD-0007 COMMENT 17
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5A.8.5 Load Speed & Slip Info 

Specified Load Speed 

Minimum Load Speed 

Speed Increment 

5A.8.6 No Load Performance 

Syn Synchronous Speed 

Snl Actual No Load Speed 

Inl Actual No Load Line Current 

GnlM No Load Main Winding Current Density 

GnlA No Load Aux. Winding Current Density 

5A.8.7 Locked Rotor Data 

Locked Rotor Torque 

Locked Rotor Line Current 

Locked Rotor Main Current Density 

Locked Rotor Aux. Current Density 

5A.8.8 Breakdown Load Parameters 

BreakDown Speed 

BreakDown Torque 

BreakDown Current 

BreakDown Output Power 

BreakDown Output Power 

BreakDown Efficiency

BreakDown Power Factor 

BreakDown Input Power

Main Current Density at BreakDown 

Aux. Current Density at BreakDown 

5A.8.9 Reactance Values 

Primary Slot Leakage 

Secondary Slot Leakage 

End Leakage 

Skew Leakage 

Zig Zag Leakage 

Belt Leakage 

Main Winding Leakage Reactance 

Rotor Leakage Referred to Main 

Auxiliary Winding Leakage Reactance 

Magnitizing Reactance of Main Winding 

 1736.0 RPM 

0.0 RPM 

10.0 RPM 

 1800.0 RPM 

1796.4 RPM 

4.44 Amps 

1539.14 Amps/sq. in 

0.00 Amps/sq. in 

51.60 lb-in 

32.111 Amps 

8483.25 A/sq. in. 

26619.81 A/sq. in. 

 1495.8 RPM 

42.25 lb-in 

16.06 Amps 

748.0 Watts 

 1.0027 Hp 

53.9 % 

0.748 

 1387.6 Watts 

5566.84 A/sq. in. 

0.00 A/sq. in. 

 0.7789 Ohms 

 0.4542 Ohms 

 0.3749 Ohms 

 1.2435 Ohms 

 0.9375 Ohms 

 0.2769 Ohms 

2.3827 Ohms 

1.6832 Ohms 

3.9179 Ohms 

45.2998 Ohms 

5A-19 

EERE-2007-BT-STD-0007 COMMENT 17
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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-T 

5A-20 

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Output Power (HP)

Torque (% of rated)

Speed (% of rated)

Torque

Power

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 Aluminum 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 Motor
 

5A-21 

EERE-2007-BT-STD-0007 COMMENT 17
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Speed (% of rated)

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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 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.9.2 Rotor Dimensions 

Shaft Material Magnetic 

Outside Diameter of the Rotor 3.3500 inch 

Inside Diameter of the Rotor 0.6250 inch 

5A-22 

EERE-2007-BT-STD-0007 COMMENT 17
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 

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.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-23 

EERE-2007-BT-STD-0007 COMMENT 17
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 Ohms 

5A-24 

EERE-2007-BT-STD-0007 COMMENT 17
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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-T 

5A-25 

EERE-2007-BT-STD-0007 COMMENT 17
 

 

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Torque (% of rated)

Speed (% of rated)

Torque

Power

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Current (Amperes)

Speed (% of rated)

L Current

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 Motor 

5A-26 

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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 inch 

5A-27 

EERE-2007-BT-STD-0007 COMMENT 17
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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. 

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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 % 

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EERE-2007-BT-STD-0007 COMMENT 17
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

0%

50%

100%

150%

200%

250%

300%

350%

400%

450%

500%

0% 20% 40% 60% 80% 100% 120%

Output Power(HP)

Torque (% of rated)

Speed (% of rated)

Torque

Power

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 Motor 

5A-30 

EERE-2007-BT-STD-0007 COMMENT 17
0

10

20

30

40

50

60

0% 20% 40% 60% 80% 100% 120%

Current (Amperes)

Speed (% of rated)

L Current

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-31 

EERE-2007-BT-STD-0007 COMMENT 17
 

 

 

 

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 Steel 

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. 

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EERE-2007-BT-STD-0007 COMMENT 17
$0.00

$500.00

$1,000.00

$1,500.00

$2,000.00

$2,500.00

76 78 80 82 84 86 88 90

Manufacturer Selling Price (2008$)

Full Load Efficiency (%)

Avg. Prices

Max. Prices

Min. Prices

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 

(2008$) 

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 Motors 

5A-33 

EERE-2007-BT-STD-0007 COMMENT 17
 

$0.00

$50.00

$100.00

$150.00

$200.00

$250.00

$300.00

$350.00

$400.00

$450.00

76 78 80 82 84 86 88 90

Manufacturer Selling Price (2008$)

Full Load Efficiency (%)

Avg. Prices

Max. Prices

Min. Prices

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 

Motors 

5A-34 

EERE-2007-BT-STD-0007 COMMENT 17
$0.00

$200.00

$400.00

$600.00

$800.00

$1,000.00

$1,200.00

$1,400.00

$1,600.00

55 60 65 70 75 80

Manufacturer Selling Price (2008$)

Full Load Efficiency (%)

Avg. Prices

Max. Prices

Min. Prices

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 Motors 

5A-35 

EERE-2007-BT-STD-0007 COMMENT 17
 

 

$0.00

$20.00

$40.00

$60.00

$80.00

$100.00

$120.00

$140.00

$160.00

$180.00

55 60 65 70 75 80

Manufacturer Selling Price (2008$)

Full Load Efficiency (%)

Avg. Prices

Max. Prices

Min. Prices

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 Motors 

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EERE-2007-BT-STD-0007 COMMENT 17
$0.00

$500.00

$1,000.00

$1,500.00

$2,000.00

$2,500.00

70 75 80 85 90

Manufacturer Selling Price (2008$)

Full Load Efficiency (%)

Avg. Prices

Max. Prices

Min. Prices

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 Motors 

5A-37 

EERE-2007-BT-STD-0007 COMMENT 17
 

 

$0.00

$50.00

$100.00

$150.00

$200.00

$250.00

$300.00

$350.00

$400.00

$450.00

70 75 80 85 90

Manufacturer Selling Price (2008$)

Full Load Efficiency (%)

Avg. Prices

Max. Prices

Min. Prices

 

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 test 

procedures: 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. 

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EERE-2007-BT-STD-0007 COMMENT 17
 

 

 

 

 

 

 

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 kW 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. 

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EERE-2007-BT-STD-0007 COMMENT 17
Table 12.3 Scaled Efficiency Levels for Baseline Polyphase Small Electric Motors 

Horsepower/Standard 

Kilowatt Equivalent 

Six Poles 

Efficiency (%) 

Four Poles 

Efficiency (%) 

Two Poles 

Efficiency (%) 

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 77.1 

5A-40 

EERE-2007-BT-STD-0007 COMMENT 17
REFERENCES
 

1 U.S. Department of Labor, Bureau of Labor Statistics, Producer Price Indices. Last accessed April 

12, 2009. <http://www.bls.gov/ppi>. 

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