# Underwriters Laboratories Inc. ®

September 17, 2001 333 Pfingsten Road Northbrook, Illinois 60062-2096 (847) 272-8800 MCI Mail No. 254-3343 Telex No. 6502543343

all log' a century of public safety A 1694.1994

Subject: Test Procedure in accordance with Federal Register 10 CFR Part 431 This is in regard to discussions concerning the qualifications of UL Engineering staff to conduct efficiency testing in accordance with the Final Ruling of Federal Register 10 CFR, Part 431 (FR). The FR requires motors to have the efficiency measured in accordance with IEEE, Standard 112-1996 (with modifications as outlined in Parts II(B)(2)(a-c), or as outlined in CSA Standard C390-93, method B. Based on years of experience evaluating products in accordance with Canadian Standards, and the industry practice of using CSA Standard, C390-93, method B for energy efficiency calculation, UL trained the staff using this document. The test procedures outlined in CSA C390-93 are similar to those procedures already in place in other Canadian standards as well as UL standards. The data and information recorded for energy verification testing, is some of the same data and information required under our current test procedures. The only exception is the measurement of the motor torque, which is 1) available for recording at UL and 2) easily recorded using a standard Dynamometer and Power Analyzer setup, and the actual calculation of efficiency, which has been converted into an automated spreadsheet to avoid errors common to data-intensive calculations. The testing UL conducts on a routine basis are covered under UL, 1004 (Electric Motors), UL 2111 (Overheating Protection for Motors, formerly UL 5 19 (Impedance Protected Motors) and UL 547 (Thermally Protected Motors)), CSA C22.2 No. 77 (Overheating Protection for Motors), and CSA C22.2 No. 100 (Motors and Generators). The attached appendix A is a tabulation of the test procedure in CSA C390-93, method B, with reference to similar procedures in UL and/or CSA Standards.

A not-for-profit organization dedicated to public safety and committed to quality servicePage Two September 17, 2001

C390 Test Procedure Familiarity (cont.)

Each person involved in the Energy Efficiency Verification Program had a minimum of 3 years experience evaluating motors in accordance with the above standards. The average number of new projects handled per year using these standards is estimated to be more than 60 projects per person. Each person also received training on thermocouple placement, temperature recording, and the use of common data acquisition equipment for approximately three months. Below is a summary of the current years experience with the relevant documents:
Lenore Berman: 10 years experience with UL 1004, UL, 2111 (UL, 519, UL 547); and

5 years experience with CSA C22.2 No. 77, 100. Roberta King : 13 years experience with UL 1004, UL 2111 (UL 519, UL 547);

7 years experience with CSA C22.2 No. 77, 100; and 5 years experience with IEC 34, 335.
Kirk Anderson: 5 years experience with UL 1004, UL, 2111 (UL 519, UL 547); and

5 years experience with CSA C22.2 No. 77, 100. Darrin Conlon: 9 years experience with UL, 1004, UL 2111 (UL 519 and UL 547) and

7 years experience with CSA 22.2 No. 77, 100 M-like Rizzo: 4 years experience with UL. 1004, UL 2111 (UL 519, UL 547); and

4 years experience with CSA C22.2 No. 77, 100. Additionally provided is a photograph of UL's motor test setup. This shows some of the equipment that is used on a regular basis to conduct our standard motor investigations. For additional information, please contact us.September 17, 2001

Appendix A, CSA C390- 93, Method B Test Procedure Breakdown
CSA C390 Test Procedure: Equivalent: Install thermocouples UI. 2111, Winding Slots (located outside air path) CSA C22.2 No. 100 Winding Ends (located outside air path) Ambient Measure Stator Resistance UL 2111, Section 5.4; CSA C22.2 No. 100, Table 4 Operate at rated Voltage, frequency, and Full load UL 2111, Section 13, UI. 1004, (Current or Torque) until thermal equilibrium Section 22; CSA C22.2 No. 77, Clause 5.3, CSA C22.2 No. 100. Clause 6.2 Operate at 2 load points above 100% and not UL 2111, Section 13; exceeding 150%, followed by 4 load points between CSA C22.2 No. 77, Clause 5.3 100% and 25% equally spaced (in descending order) I Measure voltage (for each phase), current (for each UL 2111, Section 13; phase), input wattage, speed, output (corrected), CSA C22.2 No. 77, Clause 5.3 frequency, torque, stator resistance (measured or calculated), maximum winding temperature, and ambient Disconnect load and operate at rated voltage and UL 2111, Section 13; frequency until thermal equilibrium CSA C22.2 No. 77, Clause 5.3 Vary the voltage at three points between 125 and UL 1004, Section 22, UL 2111, 60%, and three points between 50 and 20% Section 13; CSA C22.2 No. 77, Clause 5.3 Measure voltage (for each phase), current (for each UL 1004, Section 23, UL 2111, phase), input wattage, speed, output (corrected), Section 13; frequency, torque, stator resistance (measured or CSA C22.2 No. 77, Clause 5.3 calculated), maximum winding temperature, and ambient Measure watts, speed, torque, current, voltage, and UL 2111, Section 13; stator line resistance (motor coupled to dyno, and CSA C22.2 No. 77, Clause 5.3 uncoupled) Calculate efficiency Use Eff33.xls programAPPENDIX A: Comparison of CSA C390 Test Procedures to Safety Test Procedures for Electric Motors

CSA C390 Test Procedure: Equivalent safety test procedure: Install thermocouples UL 2111, Winding Slots (located outside air path) CSR C22.2 No. 100 Winding Ends (located outside air path) Ambient Measure Stator Resistance UL 2111, Section 5.4; CSA C22.2 No. 100, Table 4 Operate at rated Voltage, frequency, and UL 2111, Section 13, UL 1004, Full load (Current or Torque) until thermal Section 22; equilibrium CSA C22.2 No. 77, Clause 5.3, CSA C22.2 No. 100, Clause 6.2 Operate at 2 load points above 100% and UL 2111, Section 13; not exceeding 150%, followed by 4 load CSA C22.2 No. 77, Clause 5.3 points between 100% and 25% equally spaced (in descending order) Measure voltage (for each phase), current UL 2111, Section 13; (for each phase), input wattage, speed, CSA C22.2 No. 77, Clause 5.3 output (corrected), frequency, torque, stator resistance (measured or calculated), maximum winding temperature, and ambient Disconnect load and operate at rated voltage UL 2111, Section 13; and frequency until thermal equilibrium CSA C22.2 No. 77. Clause 5.3 Vary the voltage at three points between 125 UL 1004, Section 22, UL 2111, and 60%, and three points between 50 and Section 13; 20% CSA C22.2 No. 77, Clause 5.3 Measure voltage (for each phase), current UL 1004, Section 23, UL 2111, (for each phase), input wattage, speed, Section 13; output (corrected), frequency, torque, stator CSA C22.2 No. 77, Clause 5.3 resistance (measured or calculated), maximum winding temperature, and ambient Measure watts, speed, torque, current, UL 2111, Section 13; voltage, and stator line resistance (motor CSA C22.2 No. 77, Clause 5.3 coupled to dyno, and uncoupled) Calculate efficiency Use Eff33.xls program
UL 2111 is comprised of requirements formerly found in UL 519 and UL 547, which have been superceded by UL 2111.APPENDIX B

Personnel Experience in test standards/methods related to CSA C 390.

UL 1004 UL 2111 CSA 22.2 No. 77 CSA 22.2 No

100 Lenore Berman 10 10 5 5 Roberta King 13 13 7 7 Kirk Anderson 5 5 5 5 Darrin Conlon 9 9 7 7 Mike Rizzo 1 4 1 4 

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# Underwriters Laboratories Inc. @)

September 20, 2001 333 Pfingsten Road Northbrook, Illinois 60062-2096 (847) 272-8800 MCI Mail No. 254-3343 Telex No. 6502543343

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Subject: Test Procedure in accordance with Federal Register 10 CFR Part 431 This is in regard to discussions concerning the qualifications of UL Engineering staff to conduct efficiency testing in accordance with the Final Ruling of Federal Register 10 CFR, Part 431 (FR). The FR requires motors to have the efficiency measured in accordance with IEEE Standard 112-1996 (with corrections as outlined in Parts II(B)(2)(a-c) of the FR), or CSA Standard C390-93 method B. Based on our experience evaluating motors in accordance with CSA International motor Standard C22.2 Nos. 77 and 100, and the industry practice of using CSA Standard C390- 93 method B for energy efficiency calculations, UL staff were trained in the CSA C390- 93 document. The test procedures outlined in CSA C390-93 method B are similar to those procedures already in place in other CSA standards as well as UL standards used for motor evaluations. The data and information recorded for energy verification testing is some of the same data and information required under our current test procedures. The only exception is the measurement of the motor torque, which is 1) available for recording at UL and 2) easily recorded using a standard Dynamometer and Power Analyzer setup, equipment used in our current testing, and 3) the actual calculation of efficiency, whichhas been converted into an automated spreadsheet to avoid errors common to dataintensive calculations. The testing UL conducts on a routine basis are covered under UL 1004 (Electric Motors), UL 2111 (Overheating Protection for Motors , formerly UL 519 (Impedance Protected Motors) and UL 547 (Thermally Protected Motors )), CSA C22.2 No. 77 (Overheating Protection for Motors ), and CSA C22.2 No. 100 (Motors and Generators).

A not-for-profit organization dedicated to public safety and committed to quality servicePage Two September 20, 2001

Test Procedure (cont.)

The attached Appendix A tabulates a comparison of the test procedures in IEEE 112- 1996 with corrections , and CSA C390-93 method B, with similar procedures in UL Standards

. This table shows that the data required for energy efficiency calculation by the IEEE and CSA Standards is also measured and recorded when testing products in accordance with UL Standards, specifically UL 2111. Prior to their involvement in the Energy Efficiency Verification program, each of the following UL staff had a minimum of three years experience evaluating motors in accordance with the above safety standards. Also, each person handles an average of 60 new project evaluations annually. All staff received training on thermocouple placement, temperature recording, and the use of common data acquisition equipment. Below is a summary of the experience with the CSA and UL safety standards: Lenore Berman: 10 years experience with UL 1004, UL 2111 (UL 519, UL 547); and

5 years experience with CSA C22.2 No. 77, 100. 4 years experience with CSA C390-93 and IEEE 112-1996 Roberta King: 13 years experience with UL 1004, UL 2111 (UL 519, UL 547);

7 years experience with CSA C22.2 No. 77, 100; and 3 years experience with CSA C390-93 and IEEE 112-1996
Darrin Colon: 9 years experience with UL 1004, UL 2111 (UL 519, UL 547);

7 years experience with CSA C22.2 No. 77, 100. 1 year experience with CSA C390-93 and IEEE 112-1996 Kirk Anderson: 5 years experience with UL 1004, UL 2111 (UL 519, UL 547); and

5 years experience with CSA C22.2 No. 77, 100. 2 years experience with CSA C390-93 and IEEE 112-1996 Mike Rizzo: 4 years experience with UL 1004, UL 2111 (UL 519, UL 547); and

4 years experience with CSA C22.2 No. 77, 100. 1 year experience with CSA C390-93 and IEEE 112-1996 Also provided is a photograph of UL's motor test setup

. This shows some of the equipment, including dynamometer and power analyzer, used on a regular basis to conduct our standard motor investigations. For additional information, please contact us.

### September 20, 2001 Appendix A, FR Data Measurement Requirements Versus

UL Data Measurement Requirements

IEEE 112-1996 CSA C390-93 Method B UL 2111(tt) 5.1.1 (measure stator resistance) 5.1.1 (install thermocouples 5.2 -5.3 (install minimum 4 thermocouples and measure stator resistance) 5.4 (measure stator resistance for COR measurements) 5.3 (operate motor at rated V. Hz 5.1.2 (apply rated V,Hz, and 13.1.1.1 (apply nominal V, Hz, and full load and no-load until TE full load to motor until TE) to motor until TE) 6.4.1.1-6.4.1.2 (operate at 6 5.1.3 (operated at total 6 load 13.1.1.1 (operate at full load, increase equally spaced points between points between 150%-25% of loading, measure W, A, S, T, Am) 150%-25%, measure W, A, V, full load, equally spaced, Hz, SL, TO, Am, T) measure TO, W. A. S, T, Am) 6.4.1.3 (operate under no-load, 5.1.4-5 (operate under no-load 13.3 (operate motor under no-load vary voltage, measure V, A, W) conditions, vary voltage, conditions, measure V, A, W, T) measure V, A, W, T) 7.6 (vary voltage for increased heating, measure V, A, W, T)
A - Current Am - Ambient COR - Change-of-Resistance Hz - Frequency S - Speed SL - Slip T - Temperature TE - Thermal Equilibrium TO - Torque V - Voltage W - Input Power
(if) - Note, CSA Standard C22.2 No. 77-95 (Overheating Protection for Motors), has similar requirements, except covered under Clauses 5.3 and 5.3.3 of UL 2111. UL 1004 (Electric Motors),and CSA C22.2 No. 100 (Motors and Generators) contain testing that covers temperature testing at rated load, voltage, frequency and speed (similar to UL 2111, Sec. 13.1 and CSA C22.2 No. 77, Clause 5.3).

Calculation Of Motor Efficiency: Data obtained (Voltage, Frequency, Speed, Temperature, etc.) is used in standard formulas to calculate the stray load loss, windage friction loss, core loss, etc. These formulas (taken from IEEE 112-1996) have been put into a program to reduce the time needed to perform these calculations. An example of the utilization of the program is provided as Appendix B.Lenore. J.Berman@us . To: Jim.Raba@ee.doe.gov ul.com cc:

Jim, 10/02/01 05:44 PM Subject: Competency and Statistical Documents

Based on our discussion this afternoon, I've attached the documents that Gordon Gillerman had brought to you on September 20th. If you have any questions regarding the content of the documents, please contact me. 1. Staff Competency documentation: (See attached file: c390b•doc)(See attached file: 2pole•eff) 2. Statistical Sampling (See attached file: sampling cover.doc)(See attached file: Statistical Sample Selection•doc) Regards, E-Mail Message From:
Lenore Berman Associate Manager Underwriters Laboratories Inc. Phone: (847) 272-8800 Ext. 42848 Fax: (847) 509-6226 Email: lenore•j•berman@us•ul•com (See attached file: c390b.doc) (See attached file: 2pole.eff) (See attached file: sampling cover.doc) (See attached file: Statistical Sample Selection.doc)

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c390b.doc 2pole.eff sampling cover.doc

# Underwriters Laboratories Inc.®

333 Pfingsten Road Northbrook, Illinois 60062-2096 (847) 272-8800 MCI Mail No. 254-3343 Telex No. 6502543343

®®; a century of ^c public safety 1894-1994 A not-for-profit organization dedicated to public safety and committed to quality service

September 20. 2001

Subject: Test Procedure in accordance with Federal Register 10 CFR Part 431 This is in regard to discussions concerning the qualifications of UL Engineering staff to conduct efficiency testing in accordance with the Final Ruling of Federal Register 10 CFR, Part 431 (FR). The FR requires motors to have the efficiency measured in accordance with IEEE Standard 112-1996 (with corrections as outlined in Parts II(B)(2)(a-c) of the FR), or CSA Standard C390-93 method B. Based on our experience evaluating motors in accordance with CSA International motor Standard C22.2 Nos. 77 and 100. and the industry practice of using CSA Standard C390-93 method B for energy efficiency calculations, UL staff were trained in the CSA C390-93 document. The test procedures outlined in CSA C390-93 method B are similar to those procedures already in place in other CSA standards as well as UL standards used for motor evaluations. The data and information recorded for energy verification testing is some of the same data and information required under our current test procedures. The only exception is the measurement of the motor torque, which is 1) available for recording at UL and 2) easily recorded using a standard Dynamometer and Power Analyzer setup.equipment used in our current testing, and 3) the actual calculation of efficiency, which

has been converted into an automated spreadsheet to avoid errors common to data-intensive calculations. The testing UL conducts on a routine basis are covered under UL 1004 (Electric Motors). UL 2111 (Overheating Protection for Motors, formerly UL 519 (Impedance Protected Motors) and UL 547 (Thermally Protected Motors)), CSA C22.2 No. 77 (Overheating Protection for Motors), and CSA C22.2 No. 100 (Motors and Generators).Page Two September 20, 2001

Test Procedure (cont.)

The attached Appendix A tabulates a comparison of the test procedures in IEEE 112- 1996 with corrections, and CSA C390

-93 method B, with similar procedures in UL Standards. This table shows that the data required for energy efficiency calculation by the IEEE and CSA Standards is also measured and recorded when testing products in accordance with UL Standards , specifically UL 2111. Prior to their involvement in the Energy Efficiency Verification program, each of the following UL staff had a minimum of three years experience evaluating motors in accordance with the above safety standards. Also, each person handles an average of 60 new project evaluations annually. All staff received training on thermocouple placement, temperature recording, and the use of common data acquisition equipment. Below is a summary of the experience with the CSA and UL safety standards: Lenore Berman: 10 years experience with UL 1004, UL 2111 (UL 519, UL 547); and

5 years experience with CSA C22.2 No. 77, 100. Roberta King : 13 years experience with UL 1004, UL 2111 (UL 519, UL 547);

7 years experience with CSA C22.2 No. 77 , 100; and
Darrin Colon: 9 years experience with UL 1004, UL 2111 (UL 519, UL 547);

7 years experience with CSA C22.2 No. 77, 100.
Kirk Anderson : 5 years experience with UL 1004, UL 2111 (UL 519, UL 547); and

5 years experience with CSA C22.2 No. 77, 100. Mike Rizzo: 4 years experience with UL 1004, UL 2111 (UL 519, UL 547); and

4 years experience with CSA C22.2 No. 77, 100.

Also provided is a photograph of UL's motor test setup. This shows some of the equipment, including dynamometer and power analyzer, used on a regular basis to conduct our standard motor investigations. For additional information, please contact us.September 20, 2001 Appendix A. FR Data Measurement Requirements Versus

UL Data Measurement Requirements

IEEE 112-1996 CSA C390-93 Method B UL 2111(+t ) 5.1.1 (measure stator resistance ) 5.1.1 (install thermocouples 5.2 -5.3 ( install minimum 4 thermocouples and measure stator resistance) 5.4 (measure stator resistance for COR measurements) 5.3 (operate motor at rated V, Hz 5.1.2 (apply rated V,Hz, and 13.1.1.1 (apply nominal V. Hz, and full load and no-load until TE full load to motor until TE) to motor until TE) 6.4.1.1-6.4.1.2 (operate at 6 5.1.3 (operated at total 6 load 13.1.1.1 (operate at full load, increase equally spaced points between points between 150%-25% of loading, measure W , A, S, T, Am) 150%-25%. measure W. A. V, full load. equally spaced, Hz, SL, TO, Am, T) measure TO. W, A. S, T. Am) 6.4.1.3 (operate under no-load, 5.1.4-5 (operate under no-load 13.3 (operate motor under no-load vary voltage, measure V, A. W) conditions. vary voltage, conditions, measure V, A, W, T) measure V. A, W, T) 7.6 (vary voltage for increased heating, measure V, A, W. T)

A - Current Am - Ambient COR - Change- of-Resistance Hz - Frequency S - Speed SL - Slip T - Temperature TE - Thermal Equilibrium TO - Torque V - Voltage W - Input Power
(t 1i') - Note, CSA Standard C22.2 No. 77-95 (Overheating Protection for Motors), has similar requirements , except covered under Clauses 5.3 and 5 .3.3 of UL 211 1. UL 1004 ( Electric Motors).and CSA C22.2 No. 100 ( Motors and Generators ) contain testing that covers temperature testing at rated load , voltage. frequency and speed (similar to UL 2111. Sec. 13.1 and CSA C22.2 No. 77, Clause 5.3).
Calculation Of Motor Efficiency: Data obtained (Voltage, Frequency, Speed, Temperature, etc.) is used in standard formulas to calculate the stray load loss, windage friction loss, core loss, etc. These formulas (taken from IEEE 112-1996) have been put into a program to reduce the time needed to perform these calculations. An example of the utilization of the program is provided as Appendix B.