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

5A-i5A.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

5A-iiLIST 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 fo r 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 fo r Non-Space Constrained CSIR Motors*

........ 36 Table 11.6 Commodity Price Impact on M SP 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 fo r Baseline CSIR Small Electric Motors

......................... 40 Table 12.5 Scaled Efficiency Levels fo r 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 vers us 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 Sp eed 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 ve rsus 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 Sp eed 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 Sp eed for Efficiency Level 3, Space-Constrained, Figure 9.1 Torque and Output Power ve rsus Speed for Baseline CSCR Motor

.......................... 26 Figure 9.2 Line Current versus Speed for Baseline CSCR Motor

............................................... 26

CSCR Moto r

............................................................................................................... 30

............................................................................................................................... ...... 31 Figure 10.2 Line Current versus Speed for E fficiency 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 fo r 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 M SP for Non-Space Constrained CSCR Motors

....... 38

5A-iiiAPPENDIX 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 fo r 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 ( μ F) N/A 333 433 Run Capacitance ( μ F) 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 de termined 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 moto rs all had the same pole configuration and horsepower rating as the representative product cla ss, 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$75 $95 $115 $135 $155 $175 $195

55 60 65 70 75 80Manufacturer Selling Price ($2008)

Full Load Efficiency (%) Space Constrained

Non-Space Constrained

Tested Motors determined using the subcontractor’s modeled de signs. 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$75 $125 $175 $225 $275 $325 $375

70 75 80 85 90Manufacturer Selling Price ($2008)

Full Load Efficiency (%) Space Constrained

Non-Space Constrained
Tested Motors

$0 $50 $100 $150 $200 $250 $300 $350

73 78 83 88 93Manufacturer Selling Price ($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-Fr ame Motor Engineerin g 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 c onfirms that DOE’s cost-efficie ncy curves are sufficient in

5A-3estimating the actual cost of achieving an effi ciency 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 ar e 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

5A-4Number 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-55A.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

5A-60 0.5 1 1.5 2 2.5 3

0% 50% 100% 150% 200% 250% 300% 350%

0% 20% 40% 60% 80% 100% 120%OutputPower(HP)Torque(%ofrated)

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-70 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

5A-8Inside 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-95A.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 %

5A-10Slot 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-110 0.5 1 1.5 2 2.5 3

0% 50% 100% 150% 200% 250% 300% 350%

0% 20% 40% 60% 80% 100% 120%OutputPower(HP)Torque(%ofrated)

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-125A.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-13Outside 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-145A.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-150 0.2 0.4 0.6 0.8 1 1.2

0% 50% 100% 150% 200% 250% 300% 350%

0% 20% 40% 60% 80% 100% 120%OutputPower(HP)Torque(%ofrated)

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 vers us Speed for Baseline CSIR Motor

5A-160 5 10 15 20 25 30 35 40 45 50

0% 20% 40% 60% 80% 100% 120%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-17Inside 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-185A.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-195A.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-200 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%OutputPower(HP)Torque(%ofrated)

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-210 5 10 15 20 25 30 35 40 45 50

0% 20% 40% 60% 80% 100% 120%Current(Amperes)

Speed (% of rated) L Current

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-22Length 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-23Wire 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-24Magnitizing 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-250 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6

0% 50% 100% 150% 200% 250% 300% 350% 400% 450%

0% 20% 40% 60% 80% 100% 120%OutputPower(HP)Torque(%ofrated)

Speed (% of rated) Torque

Power

0 10 20 30 40 50 60

0% 20% 40% 60% 80% 100% 120%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 vers us Speed for Baseline CSCR Motor

Figure 9.2 Line Current versus Speed for Baseline CSCR Motor

5A-265A.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-27Inside 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-285A.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-290 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%OutputPower(HP)Torque(%ofrated)

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-300 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 alu minum 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 co mmodities, 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 ad justed historical prices to $2008 using the
historical Bureau of Labor Sta tistics Producer Price Indices (PPI) 1 for each commodity’s industry. Table 11.1 summarizes the historical five-year prices in terms of 2008$, and also shows the average price point DOE used for its analysis.

5A-31Table 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.

5A-32$0.00 $500.00 $1,000.00 $1,500.00 $2,000.00 $2,500.00

76 78 80 82 84 86 88 90Manufacturer 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$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 90Manufacturer 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$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 80Manufacturer 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$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 80Manufacturer Selling Price (2008$)

Full Load Efficiency (%) Avg. Prices

Max. Prices

Min. Prices Table 11.5 Commodity Price Impact on MSP fo r 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 fo r Non-Space Constrained CSIR Motors

5A-36$0.00 $500.00 $1,000.00 $1,500.00 $2,000.00 $2,500.00

70 75 80 85 90Manufacturer Selling Price (2008$)

Full Load Efficiency (%) Avg. Prices

Max. Prices

Min. Prices Table 11.6 Commodity Price Impact on MS P 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 MS P for Space Constrained CSCR Motors

5A-37$0.00 $50.00 $100.00 $150.00 $200.00 $250.00 $300.00 $350.00 $400.00 $450.00

70 75 80 85 90Manufacturer 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.

5A-38Table 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 deter mine the appropriate efficiency levels for the remaining product classes. Table 12.3 through Tabl e 12.5 show the scaled efficiency levels for each product class at the baseline efficiency level.

5A-39Table 12.3 Scaled Efficiency Levels for Ba seline 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-40REFERENCES

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

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