5A

- i APPENDIX 5A. ENGINEERING DATA

TABLE OF CONTENTS

5A.1 INTRODUCTION

................................ ................................ ................................ ........................... 1

5A.2 BASELINE AND MAXIMUM TECHNOLOGY DESIGN SU MMARIES

................................ .. 1

5A.3 DESIGN SPECIFICATION S AND LOAD PERFORMAN CE OF BASELINE MOTOR S

.......... 2

5A.3.1 5

- Horsepower, NEMA Design B, Baseline Data and IEEE 112B Test Results

.................. 3

5A.3.2 30

- Horsepower, NEMA Design B , Baseline Data and IEEE 112B Test Results

................ 4

5A.3.3 75

- Horsepower, NEMA Design B, Baseline Data and IEEE 112B Test Results

................ 6

5A.3.4 5 Horsepower, NEMA Design C, Baseline Data and IEEE 112B Test Results

................... 7

5A.3.5 50

- Horsepower, NEMA Design C, Baseline Data and IEEE 112B Test Results

................ 9

5A.4 DESIGN SPECIFICATION S AND LOAD PERFORMAN CE OF MAXIMUM TECHNO LOGY

MOTORS

................................ ................................ ................................ ................................ ....... 10

5A.4.1 5

- Horsepower, NEMA Design B, Maximum Technology Data and Modeling Results

.... 10

5A.4.2 30

- Horsepower, NEMA Design B, Maximum Technology Data and Modeling Results

.. 11

5A.4.3 75

- Horsepower, NEMA Design B, Maximum Technology Data and Modeling Results

.. 12

5A.4.4 5

- Horsepower, NEMA Design C, Maximum Technology Data and Modeling Results

.... 13

5A.4.5 50

- Horsepower, NEMA Design C, Maximum Technology Data and Modeling Results

.. 14

5A.5 CANDIDATE STANDARD L EVELS OF EFFICIENCY

................................ ........................... 15

5A.6 MATE RIAL PRICING ASSUMPT IONS

................................ ................................ ..................... 25

5A.6.1 Copper Wire Pricing

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

5A.6.2 2011 Material Pricing

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

5A.7 LABOR TIME AND COST ASSUMPTIONS

................................ ................................ .............. 27

LIST OF TABLES

Table 2.1 Baselin e Design Data

................................ ................................ ................................ .......... 1

Table 2.2 Maximum Technology Design Data of Software Modeled Motors

................................ .... 2

Table 3.1 5

- Horsepower, NEMA Design B, Nameplate Data

................................ ............................ 3

Table 3.2 5

- Horsepower, NEMA Design B, IEEE 112B Test Results (460 Volts)

............................ 3

Table 3.3 30

- Hors epower, NEMA Design B, Nameplate Data

................................ .......................... 4

Table 3.4 30

- Horsepower, NEMA Design B, IEEE 112B Test Results (460 Volts)

.......................... 5

Table 3.5 75

- Horsepower, NEMA Design B, Nameplate Data

................................ .......................... 6

Table 3.6 75

- Horsepower, NEMA Design B, IEEE 112B Test Results (460 Volts)

.......................... 6

Table 3.7 5 Horsepower NEMA Design C Nameplate Data

................................ .............................. 7

Table 3.8 5

- Horsepower, NEMA Design C, IEEE 112 B Test Results

................................ ............... 8

Table 3.9 50

- Horsepower, NEMA Design C, Nameplate Data

................................ .......................... 9

Table 3.10 50

- Horsepower, NEMA Design C, IEEE 112B Test Results

................................ ............. 9

Table 4.1 5

- Horsepower, NEMA Design B, Computer Modeling Data

................................ ........... 10

Table 4.2 30

- Horsep ower, NEMA Design B, Computer Modeling Data

................................ ......... 11

Table 4.3 75

- Horsepower, NEMA Design B, Computer Modeling Data

................................ ......... 12

Table 4.4 5

- Horsepower, NEMA Design C, Computer Modeling Data

................................ ........... 13

Table 4.5 50

- Horsepower, NEMA Design C, Computer Modeling Data

................................ ......... 14

Table 5.1 NEMA Design A & B Electric Motors at CSL 0

................................ .............................. 16

Table 5.2 NEMA Design A & B Electric Motors at CSL 1

................................ .............................. 17

Table 5.3 NEMA Design A & B Electric Motors at CSL 2

................................ .............................. 185A

- ii Table 5.4 NEMA Design A & B Electric Motors at CSL 3

................................ .............................. 19

Table 5.5 NEMA Design A & B Electric Motors at CSL 4

................................ .............................. 20

Table 5.6 NEMA Design A & B Electric Motors at CSL 5

................................ .............................. 21

Table 5.7 NEMA Design C Electric Motors at CSL 0

................................ ................................ ...... 22

Table 5.8 NEMA Design C Electric Motors at CSL 1

................................ ................................ ...... 23

Table 5.9 NEMA Design C Electric Motors at CSL 2

................................ ................................ ...... 24

T able 5.10 NEMA Design C Electric Motors at CSL 3

................................ ................................ ...... 25

Table 6.1 Copper Material Pricing

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

Table 6.2 Material Pricing in Constant 2011$

................................ ................................ .................. 27

Table 7.1 Labor Hour Assumptions by Candidate Standard Level (CSL)

................................ ....... 28

Table 7.2 Slot Fill Percentages by Candidate Standard Level (CSL)

................................ ............... 28

LIST OF FIGURES

Figure 3.1 5

- Horsepower, NEMA Design B, Ef ficiency and Power Factor versus Load

.................... 4

Figure 3.2 30

- Horsepower, NEMA Design B, Efficiency and Power Factor versus Load

.................. 5

Figure 3.3 75

- Horsepower NEMA Design B Efficiency and Power Factor versus Load

.................... 7

Figure 3.4 5

- Horsepower, NEMA Design C, Efficiency and Power Factor versus Load

.................... 8

Figure 3.5 50

- Horsepower, NEMA Design C, Efficiency and Power Factor versus Load

................ 10

Figure 4.1 5

- Horsepower, NEMA Design B, Efficiency and Power Factor versus Load

.................. 11

Figure 4.2 30

- Horsepower, NEMA Design B, Efficiency and Power Factor versus Load

................ 12

Figure 4.3 75

- Horsepower, NEMA Design B, Efficiency and Power Factor versus Load

................ 13

Figure 4.4 5

- Horsepower, NEMA Design C, Efficiency and Power Factor versus Load

.................. 14

Figure 4.5 50

- Horsepower, NEMA Design C, Efficiency and Power Factor versus Load

................ 155A

- 1 APPENDIX 5A ENGINEERING DATA

5A.1 INTRODUCTION

This appendix presents baseline specifications and detai led cost

- efficiency results for

each of the electric motor equipment classes analyzed in the engineering analysis (chapter 5).

5A.2 BASELINE AND MAXIMUM TECHNOLOGY DESIGN SU MMARIES

Table 2

. 1 and Table 2

. 2 show the baseline and maximum technology designs for each

equipment cla ss analyzed, respectively. In the engineering analysis, all changes to cost and

efficiency are measured relative the levels in Table 2

. 1 . The represe ntative motors chosen from

each equipment class are all 4

- pole, total ly enclosed

, fan

- cooled, continuous duty, 60 hertz, and

operate on less than 600 volts.

Table 2

. 1 Baseline Design Data

Parameter

(Units) Unit 5 hp

(Design B) 30 hp

(Design B) 75 hp

(Design B) 5 hp

(Design C) 50 hp

(Design C)

Efficiency % 8 2 .5 89.5 9 3.0 87.5 93.0

Power Factor % 0.8 3 0.8 6 0.8 7 0.75 0.85

Cycles Hz 60 60 60 60 60

Tested Voltage V 460 460 460 460 460

Speed RPM 1,745 1,7 5 5 1,7 7 5 1,750 1,770

Full Load

Torque Nm 20. 3 121. 6 300.5 20.3 201

Current A 6. 9 37 88 7.2 59.2

Core Steel

- M56 M56 M 56 M47 M47

Stack Length in 2.8 7.88 8.15 4.75 8.67

Rotor Material

- Aluminum Aluminum Aluminum Aluminum Aluminum

Main Wire AWG 19 1 8 1 7 18 17

Insulation Class

- F F F F F

Temperature

Rise  ̊C 76.1 74.5 53.5 63.5 64.2

Breakdown

Torque % of

Full

Load 3 00 25 0 2 05 355 257

Locked

- Rotor

Torque % of

Full

Load 2 40 2 00 1 70 326 211

Locked

- Rotor

Current A 46 21 2 50 6 45 344

Pull

- Up Torque % of

Full

Load 187 142 165 248 1595A

- 2 Table 2

. 2 Maximum Technology Design Data of Software Modeled Motors

Parameter

(Units) Unit 5 hp

(Design B) 30 hp

(Design B) 75 hp

(Design B) 5 hp

(Design C) 50 hp

(Design C)

Efficiency % 91.7 94.5 96.5 91.0 95.0

Power Factor % 0.84 0.79 0.79 0.79 0.80

Hertz Hz 60 60 60 60 60

Tested Voltage V 460 460 460 460 460

Speed RPM 1,776 1,784 1,789 1,776 1,782

Torque Nm 20.1 119.6 298.5 19.9 199.7

Current A 6.0 37.3 91.9 6.5 61.3

Core Steel

- M 36 M 36 M 36 M 36 M 36

Stack Height in 5.32 7.0 13.0 5.32 9.55

Rotor Material

- Copper Copper Copper Copper Copper

Main Wire AWG 20 18 14 18 17

Temperature

Rise  ̊C 70 70 70 70 70

Breakdown

Torque % of

Full

Load 305 202 202 260.8 233.5

Locked

- Rotor

Torque % of

Full

Load 214 164 163.7 260.8 202.9

Locked

- Rotor

Current A 43.9 208 541.3 41.7 359.6

Pull

- Up Torque % of

Full

Load 214 139 139.3 260.8 202.9

5A.3 DESIGN SPECIFICATION S AND LOAD PERFORMAN CE OF BASELINE

MOTORS

Nameplate data and results of the IEEE Standard 112 (Test Method B ) (IEEE 112B)

test ing for the baseline representative motors are displayed in sections 5A.3.1 through 5A.3.5

.5A

- 3 5A.3.1 5

- Horsepower

, NEMA Design B

, Baseline Data and IEEE 112B Test Results

Table 3

. 1 5

- Horsepower

, NEMA Design B

, Nameplate Data

Parameter Value

Phases 3

Voltage 230/460

Rated Horsepower 5.0

Rated Current 13.7/6.9

Frame 184TP

NEMA Nameplate Nominal Efficiency 82 .5%

Hertz 60

RPM 1745

Enclosure TEFC

Insulation Class F

Service Factor 1.15

Code Letter (for locked

- rotor kVA) J

Table 3

. 2 5

- Horsepower

, NEMA Design B

, IEEE 112B Test Results (460 Volts)

Load Efficiency Power Factor Current

% % % Amperes

25 73.9 47.8 3.3

50 82.5 67.9 4.2

75 84.4 77.6 5.4

100 82.5 82.7 6.9

115 82.9 84.4 7.75A

- 4 Figure 3

. 1 5

- Horsepower

, NEMA Design B

, Efficiency and Power Factor v ersus Load

5A.3.2 30

- Horsepower

, NEMA Design B

, Baseline Data and IEEE 112B Test Results

Table 3

. 3 30

- Horsepower

, NEMA Design B

, Nameplate Data

Parameter Value

Phases 3

Voltage 230/460

Rated Horsepower 30.0

Rated Current 74/37

Frame 286TPA

NEMA Nameplate Nominal Efficiency 89.5 %

Hertz 60

RPM 1755

Enclosure TEFC

Insulation Class F

Service Factor 1.15

Code Letter (for locked

- rotor kVA) G

35 45 55 65 75 85 95

25 50 75 100 115Efficiency (%) and Power Factor (%)

Full Load (%) 

## Effiency (%) and Power Factor (%) vs Load (%)

Efficiency

Power Factor5A

- 5 Table 3

. 4 30

- Horsepower

, NEMA Design B

, IEEE 112B Test Results (460 Volts)

Load Efficiency Power Factor Current

% % % Amperes

25 86.7 58.6 13.8

50 90.7 77.2 20.1

75 90.8 83.9 27.6

100 88.5 86.2 37

115 87.4 86.6 43

Figure 3

. 2 30

- Horsepower

, NEMA Design B

, Efficiency and Power Factor v ersus Load 35 45 55 65 75 85 95

25 50 75 100 115Efficiency (%) and Power Factor (%)

Full Load (%) 

## Effiency (%) and Power Factor (%) vs Load (%)

Efficiency

Power Factor5A

- 6 5A.3.3 75

- Horsepower

, NEMA Design B

, Baseline Data and IEEE 112B Test Results

Table 3

. 5 75

- Horsepower

, NEMA Design B

, Nameplate Data

Parameter Value

Phases 3

Voltage 460

Rated Horsepower 75.0

Rated Current 88.0

Frame 365TP

NEMA Nameplate Nominal Efficiency 93.0 %

Hertz 60

RPM 177 5

Enclosure TEFC

Insulation Class F

Service Factor 1.1 5

Code Letter (for locked

- rotor kVA) F

Table 3

. 6 75

- Horsepower

, NEMA Design B

, IEEE 112B Test Results (460 Volts)

Load Efficiency Power Factor Current

% % % Amperes

25 88.1 64.7 31

50 92.3 81.0 47

75 93.0 85.7 66

100 92.4 86.8 88

115 91.7 86.6 1025A

- 7 Figure 3

. 3 75

- Horsepower NEMA Design B Efficiency and Power Factor v ersus Load

5A.3.4 5 Horsepower

, NEMA Design C

, Baseline Data and IEEE 112B Test Results

Table 3

. 7 5 Horsepower NEMA Design C Nameplate Data

Parameter Value

Phases 3

Voltage 208

- 230/460

Rated Horsepower 5.0

Rated Current 15.3

- 14.16/7.08

Frame 184T

NEMA Nameplate Nominal Efficiency 87.5%

Hertz 60

RPM 1750

Enclosure TEFC

Insulation Class F

Service Factor 1.15

Code Letter (for locked

- rotor kVA) J

35 45 55 65 75 85 95 105

25 50 75 100 115Efficiency (%) and Power Factor (%)

Full Load (%) 

## Effiency (%) and Power Factor (%) vs Load (%)

Efficiency

Power Factor5A

- 8 Table 3

. 8 5

- Horsepower

, NEMA Design C

, IEEE 112B Test Results

Load Power Efficiency Power Factor Current

% HP % % Amperes

25.8 1.29 79.42 37 4.1

51.1 2.55 86.22 57 4.9

76.1 3.81 87.66 68 5.9

100.9 5.04 87.47 75 7.2

116 5.79 86.99 77 8.1

125.7 6.29 86.49 79 8.7

Figure 3

. 4 5

- Horsepower

, NEMA Design C

, Efficiency and Power Factor v ersus Load 35 45 55 65 75 85 95

25.8 51.1 76.1 100.9 116 125.7Efficiency (%) and Power Factor (%)

Full Load (%) 

## Effiency (%) and Power Factor (%) vs Load (%)

Efficiency

Power Factor5A

- 9 5A.3.5 50

- Horsepower

, NEMA Design C

, Baseline Data and IEEE 112B Test Results

Table 3

. 9 50

- Horsepower

, NEMA Design C

, Nameplate Data

Parameter Value

Phases 3

Voltage 208

- 230/460

Rated Horsepower 50.0

Rated Current 130

- 118/59

Frame 236T

NEMA Nameplate Nominal Efficiency 93.0%

Hertz 60

RPM 1770

Enclosure TEFC

Insulation Class F

Service Factor 1.15

Code Letter (for locked

- rotor kVA) F

Table 3

. 10 50

- Horsepower

, NEMA Design C

, IEEE 112B Test Results

Load Power Efficiency Power Factor Current

% HP % % Amperes

25.1 12.55 88.04 55 24.5

50.1 25.05 92.25 75 34

75.2 37.57 93.16 82 45.9

100.2 50.07 93.08 85 59.2

115.2 57.56 92.81 86 67.8

125.2 62.59 92.54 86 73.85A

- 10 Figure 3

. 5 50

- Horsepower

, NEMA Design C

, Efficiency and Power Factor v ersus Load

5A.4 DESIGN SPECIFICATION S AND LOAD PERFORMAN CE OF MAXIMUM

TECHNOLOGY MOTORS

Performance data and speed v ersus torque curves for the maximum

- technology,

computer

- modeled motors are displayed in sections 5A.4.1 through 5A.4.5

.

5A.4.1 5

- Horsepower

, NEMA Design B

, Maximum Technology Data and Modeling Results

Table 4

. 1 5

- Horsepower

, NEMA Design B

, Computer Modeling Data

Load Power Efficiency Power Factor Current

% HP % % Amperes

0 0 0 6.9 2.35

25 1.25 86.4 49.5 2.74

50 2.50 91.1 71.3 3.60

75 3.75 92.1 80.5 4.73

100 5.00 92.1 84.4 6.02

115 5.75 91.8 85.4 6.86

125 6.25 91.6 85.7 7.45

150 7.50 90.7 85.7 9.04 40 50 60 70 80 90 100

25.1 50.1 75.2 100.2 115.2 125.2Efficiency (%) and Power Factor (%)

Full Load (%) 

## Effiency (%) and Power Factor (%) vs Load (%)

Efficiency

Power Factor5A

- 11 Figure 4

. 1 5

- Horsepower

, NEMA Design B

, Efficiency and Power Factor v ersus Load

5A.4.2 30

- Horsepower

, NEMA Design B

, Maximum Technology Data and Modeling

Results

Table 4

. 2 30

- Horsepower

, NEMA Design B

, Computer Modeling Data

Load Power Efficiency Power Factor Current

% HP % % Amperes

0 0 0 5.4 12.44

25 7.50 90.3 51.5 15.10

50 14.98 93.8 71.6 20.87

75 22.49 94.7 78.6 28.28

100 29.98 94.8 80.3 36.88

115 34.49 94.7 79.8 42.76

125 37.48 94.5 78.9 47.08

150 44.95 93.5 73.8 60.97 0 10 20 30 40 50 60 70 80 90 100

0 25 50 75 100 115 125 150Efficiency (%) and Power Factor (%)

Full Load (%) 

## Effiency (%) and Power Factor (%) vs Load (%)

Efficiency

Power Factor5A

- 12 Figure 4

. 2 30

- Horsepower

, NEMA Design B

, Efficiency and Power Factor v ersus Load

5A.4.3 75

- Horsepower

, NEMA Design B

, Maximum Technology Data and Modeling

Results

Table 4

. 3 75

- Horsepower

, NEMA Design B

, Computer Modeling Data

Load Power Efficiency Power Factor Current

% HP % % Amperes

0 0 0.00 3.10 28.96

25 18.74 94.20 52.30 35.63

50 37.43 96.10 72.30 50.47

75 56.20 96.50 78.50 69.47

100 74.98 96.40 79.30 91.88

115 86.22 96.20 78.00 107.56

125 93.71 96.00 76.40 119.64

150 110.58 94.60 65.60 166.98 0 10 20 30 40 50 60 70 80 90 100

0 25 50 75 100 115 125 150Efficiency (%) and Power Factor (%)

Full Load (%) 

## Effiency (%) and Power Factor (%) vs Load (%)

Efficiency

Power Factor5A

- 13 Figure 4

. 3 75

- Horsepower

, NEMA Design B

, Efficiency and Power Factor v ersus Load

5A.4.4 5

- Horsepower

, NEMA Design C

, Maximum Technology Data and Modeling Results

Table 4

. 4 5

- Horsepower

, NEMA Design C

, Computer Modeling Data

Load Power Efficiency Power Factor Current

% HP % % Amperes

0 0.00 0.0 7.7 2.94

25 1.25 82.6 43.0 3.29

50 2.48 88.9 64.1 4.10

75 3.75 90.7 74.5 5.20

100 5.00 91.0 79.3 6.49

115 5.75 90.9 80.6 7.35

125 6.25 90.7 81.1 7.96

150 7.50 89.9 81.0 9.64

0 20 40 60 80 100 120

0 25 50 75 100 115 125 150Efficiency (%) and Power Factor (%)

Full Load (%) 

## Effiency (%) and Power Factor (%) vs Load (%)

Efficiency

Power Factor5A

- 14 Figure 4

. 4 5

- Horsepower

, NEMA Design C

, Efficiency and Power Factor v ersus Load

5A.4.5 50

- Horsepower

, NEMA Design C

, Maximum Technology Data and Modeling

Results

Table 4

. 5 50

- Horsepower

, NEMA Design C

, Computer Modeling Data

Load Power Efficiency Power Factor Current

% HP % % Amperes

0 0.00 0.00 4.50 20.08

25 12.49 91.70 52.00 24.51

50 24.96 94.50 72.20 34.25

75 37.47 95.10 78.90 46.75

100 49.96 95.00 80.30 61.35

115 57.47 94.70 79.60 71.42

125 62.47 94.40 78.50 78.96

150 74.77 93.00 72.10 104.42 0 10 20 30 40 50 60 70 80 90 100

0 25 50 75 100 115 125 150Efficiency (%) and Power Factor (%)

Full Load (%) 

## Effiency (%) and Power Factor (%) vs Load (%)

Efficiency

Power Factor5A

- 15 Figure 4

. 5 50

- Horsepower

, NEMA Design C

, Efficiency and Power Factor versus Load

5A.5 CANDIDATE STANDARD L EVELS OF EFFICIENCY

As part of the scaling process, DOE developed candidate standard levels (CSLs) of

efficiency for each equipment class group using NEMA efficiency tables and incremental

improvements of motor losses. Table 5

. 1

– Table 5

. 10 show the CSLs that were developed for the

various NEMA design letters, pole configurations, and enclosure types. 0 10 20 30 40 50 60 70 80 90 100

0 25 50 75 100 115 125 150Efficiency (%) and Power Factor (%)

Full Load (%) 

## Effiency (%) and Power Factor (%) vs Load (%)

Efficiency

Power Factor5A

- 16 Table 5

. 1 NEMA Design A & B Electric Motors at CSL 0

Horsepower Nominal Full Load Efficiency (%)

2 Pole 4 Pole 6 Pole 8 Pole

Enclosed Open Enclosed Open Enclosed Open Enclosed Open

1 75.5 75.5 75.5 77.0 74.5 80.0 66.0 72.0

1.5 74.0 80.0 77.0 80.0 75.5 75.5 72.0 75.5

2 77.0 82.5 80.0 79.0 78.5 80.0 78.0 80.0

3 80.0 84.0 78.5 80.0 81.5 82.5 80.0 78.5

5 80.0 81.5 82.5 82.5 84.0 85.5 84.5 82.5

7.5 81.5 84.0 84.0 84.0 82.5 81.5 85.5 84.0

10 82.5 85.5 86.5 87.5 84.0 87.5 84.0 85.5

15 85.5 86.5 86.5 87.5 88.5 85.5 88.5 86.5

20 88.5 88.5 87.5 88.5 87.5 87.5 89.5 86.5

25 91.0 89.5 89.5 85.5 91.7 87.5 88.5 87.5

30 89.5 88.5 89.5 87.5 89.5 87.5 91.0 89.5

40 91.0 88.5 91.0 89.5 89.5 88.5 91.0 89.5

50 92.4 88.5 91.0 89.5 90.2 90.2 91.0 91.0

60 92.4 89.5 91.7 90.2 92.4 89.5 91.0 92.4

75 93.0 89.5 93.0 91.0 92.4 89.5 92.0 93.6

100 93.6 91.0 92.4 92.4 93.0 93.0 92.0 93.6

125 94.5 93.6 92.4 93.0 93.6 93.6 92.5 93.6

150 93.6 92.4 93.6 92.4 95.0 93.0 93.6 93.6

200 95.0 93.6 94.5 93.0 94.2 94.1 93.5 93.6

250 94.5 93.6 94.6 93.6 94.0 94.5 94.0 94.5

300 95.4 95.0 94.1 94.5 94.5 95.4 94.5 94.5

350 95.4 95.0 95.0 94.5 94.9 95.0 94.5 94.5

400 95.4 95.4 95.3 95.4 94.9 95.4 94.5 94.5

450 95.4 95.8 95.4 95.4 95.0 95.4 94.5 94.5

500 95.4 95.8 95.4 95.8 95.0 95.4 94.5 94.55A

- 17 Table 5

. 2 NEMA Design A & B Electric Motors at CSL 1

Horsepower Nominal Full Load Efficiency (%)

2 Pole 4 Pole 6 Pole 8 Pole

Enclosed Open Enclosed Open Enclosed Open Enclosed Open

1 75.5 75.5 82.5 82.5 80.0 80.0 74.0 74.0

1.5 82.5 82.5 84.0 84.0 85.5 84.0 77.0 75.5

2 84.0 84.0 84.0 84.0 86.5 85.5 82.5 85.5

3 85.5 84.0 87.5 86.5 87.5 86.5 84.0 86.5

5 87.5 85.5 87.5 87.5 87.5 87.5 85.5 87.5

7.5 88.5 87.5 89.5 88.5 89.5 88.5 85.5 88.5

10 89.5 88.5 89.5 89.5 89.5 90.2 88.5 89.5

15 90.2 89.5 91.0 91.0 90.2 90.2 88.5 89.5

20 90.2 90.2 91.0 91.0 90.2 91.0 89.5 90.2

25 91.0 91.0 92.4 91.7 91.7 91.7 89.5 90.2

30 91.0 91.0 92.4 92.4 91.7 92.4 91.0 91.0

40 91.7 91.7 93.0 93.0 93.0 93.0 91.0 91.0

50 92.4 92.4 93.0 93.0 93.0 93.0 91.7 91.7

60 93.0 93.0 93.6 93.6 93.6 93.6 91.7 92.4

75 93.0 93.0 94.1 94.1 93.6 93.6 93.0 93.6

100 93.6 93.0 94.5 94.1 94.1 94.1 93.0 93.6

125 94.5 93.6 94.5 94.5 94.1 94.1 93.6 93.6

150 94.5 93.6 95.0 95.0 95.0 94.5 93.6 93.6

200 95.0 94.5 95.0 95.0 95.0 94.5 94.1 93.6

250 95.4 94.5 95.0 95.4 95.0 95.4 94.5 94.5

300 95.4 95.0 95.4 95.4 95.0 95.4 94.5 94.5

350 95.4 95.0 95.4 95.4 95.0 95.4 94.5 94.5

400 95.4 95.4 95.4 95.4 95.0 95.4 94.5 94.5

450 95.4 95.8 95.4 95.8 95.0 95.4 94.5 94.5

500 95.4 95.8 95.8 95.8 95.0 95.4 94.5 94.55A

- 18 Table 5

. 3 NEMA Design A & B Electric Motors at CSL 2

Horsepower Nominal Full Load Efficiency (%)

2 Pole 4 Pole 6 Pole 8 Pole

Enclosed Open Enclosed Open Enclosed Open Enclosed Open

1 77.0 77.0 85.5 85.5 82.5 82.5 75.5 75.5

1.5 84.0 84.0 86.5 86.5 87.5 86.5 78.5 77.0

2 85.5 85.5 86.5 86.5 88.5 87.5 84.0 86.5

3 86.5 85.5 89.5 89.5 89.5 88.5 85.5 87.5

5 88.5 86.5 89.5 89.5 89.5 89.5 86.5 88.5

7.5 89.5 88.5 91.7 91.0 91.0 90.2 86.5 89.5

10 90.2 89.5 91.7 91.7 91.0 91.7 89.5 90.2

15 91.0 90.2 92.4 93.0 91.7 91.7 89.5 90.2

20 91.0 91.0 93.0 93.0 91.7 92.4 90.2 91.0

25 91.7 91.7 93.6 93.6 93.0 93.0 90.2 91.0

30 91.7 91.7 93.6 94.1 93.0 93.6 91.7 91.7

40 92.4 92.4 94.1 94.1 94.1 94.1 91.7 91.7

50 93.0 93.0 94.5 94.5 94.1 94.1 92.4 92.4

60 93.6 93.6 95.0 95.0 94.5 94.5 92.4 93.0

75 93.6 93.6 95.4 95.0 94.5 94.5 93.6 94.1

100 94.1 93.6 95.4 95.4 95.0 95.0 93.6 94.1

125 95.0 94.1 95.4 95.4 95.0 95.0 94.1 94.1

150 95.0 94.1 95.8 95.8 95.8 95.4 94.1 94.1

200 95.4 95.0 96.2 95.8 95.8 95.4 94.5 94.1

250 95.8 95.0 96.2 95.8 95.8 95.8 95.0 95.0

300 95.8 95.4 96.2 95.8 95.8 95.8 95.0 95.0

350 95.8 95.4 96.2 95.8 95.8 95.8 95.0 95.0

400 95.8 95.8 96.2 95.8 95.8 95.8 95.0 95.0

450 95.8 96.2 96.2 96.2 95.8 96.2 95.0 95.0

500 95.8 96.2 96.2 96.2 95.8 96.2 95.0 95.05A

- 19 Table 5

. 4 NEMA Design A & B Electric Motors at CSL 3

Horsepower Nominal Full Load Efficiency (%)

2 Pole 4 Pole 6 Pole 8 Pole

Enclosed Open Enclosed Open Enclosed Open Enclosed Open

1 78.5 78.5 86.5 86.5 84.0 84.0 77.0 77.0

1.5 85.5 85.5 87.5 87.5 88.5 87.5 80.0 78.5

2 86.5 86.5 87.5 87.5 89.5 88.5 85.5 87.5

3 87.5 86.5 90.2 90.2 90.2 89.5 86.5 88.5

5 89.5 87.5 90.2 90.2 90.2 90.2 87.5 89.5

7.5 90.2 89.5 92.4 91.7 91.7 91.0 87.5 90.2

10 91.0 90.2 92.4 92.4 91.7 92.4 90.2 91.0

15 91.7 91.0 93.0 93.6 92.4 92.4 90.2 91.0

20 91.7 91.7 93.6 93.6 92.4 93.0 91.0 91.7

25 92.4 92.4 94.1 94.1 93.6 93.6 91.0 91.7

30 92.4 92.4 94.1 94.5 93.6 94.1 92.4 92.4

40 93.0 93.0 94.5 94.5 94.5 94.5 92.4 92.4

50 93.6 93.6 95.0 95.0 94.5 94.5 93.0 93.0

60 94.1 94.1 95.4 95.4 95.0 95.0 93.0 93.6

75 94.1 94.1 95.8 95.4 95.0 95.0 94.1 94.5

100 94.5 94.1 95.8 95.8 95.4 95.4 94.1 94.5

125 95.4 94.5 95.8 95.8 95.4 95.4 94.5 94.5

150 95.4 94.5 96.2 96.2 96.2 95.8 94.5 94.5

200 95.8 95.4 96.5 96.2 96.2 95.8 95.0 94.5

250 96.2 95.4 96.5 96.2 96.2 96.2 95.4 95.4

300 96.2 95.8 96.5 96.2 96.2 96.2 95.4 95.4

350 96.2 95.8 96.5 96.2 96.2 96.2 95.4 95.4

400 96.2 96.2 96.5 96.2 96.2 96.2 95.4 95.4

450 96.2 96.5 96.5 96.5 96.2 96.5 95.4 95.4

500 96.2 96.5 96.5 96.5 96.2 96.5 95.4 95.45A

- 20 Table 5

. 5 NEMA Design A & B Electric Motors at CSL 4

Horsepower Nominal Full Load Efficiency (%)

2 Pole 4 Pole 6 Pole 8 Pole

Enclosed Open Enclosed Open Enclosed Open Enclosed Open

1 80.0 80.0 87.5 87.5 85.5 85.5 78.5 78.5

1.5 86.5 86.5 88.5 88.5 89.5 88.5 81.5 80.0

2 87.5 87.5 88.5 88.5 90.2 89.5 86.5 88.5

3 88.5 87.5 91.0 91.0 91.0 90.2 87.5 89.5

5 90.2 88.5 91.0 91.0 91.0 91.0 88.5 90.2

7.5 91.0 90.2 93.0 92.4 92.4 91.7 88.5 91.0

10 91.7 91.0 93.0 93.0 92.4 93.0 91.0 91.7

15 92.4 91.7 94.1 94.1 93.0 93.0 91.0 91.7

20 92.4 92.4 94.1 94.1 93.0 93.6 91.7 92.4

25 93.0 93.0 94.5 94.5 94.1 94.1 91.7 92.4

30 93.0 93.0 94.5 95.0 94.1 94.5 93.0 93.0

40 93.6 93.6 95.0 95.0 95.0 95.0 93.0 93.0

50 94.1 94.1 95.4 95.4 95.0 95.0 93.6 93.6

60 94.5 94.5 95.8 95.8 95.4 95.4 93.6 94.1

75 94.5 94.5 96.2 95.8 95.4 95.4 94.5 95.0

100 95.0 94.5 96.2 96.2 95.8 95.8 94.5 95.0

125 95.8 95.0 96.2 96.2 95.8 95.8 95.0 95.0

150 95.8 95.0 96.5 96.5 96.5 96.2 95.0 95.0

200 96.2 95.8 96.8 96.5 96.5 96.2 95.4 95.0

250 96.5 95.8 96.8 96.5 96.5 96.5 95.8 95.8

300 96.5 96.2 96.8 96.5 96.5 96.5 95.8 95.8

350 96.5 96.2 96.8 96.5 96.5 96.5 95.8 95.8

400 96.5 96.5 96.8 96.5 96.5 96.5 95.8 95.8

450 96.5 96.8 96.8 96.8 96.5 96.8 95.8 95.8

500 96.5 96.8 96.8 96.8 96.5 96.8 95.8 95.85A

- 21 Table 5

. 6 NEMA Design A & B Electric Motors at CSL 5

Horsepower Nominal Full Load Efficiency (%)

2 Pole 4 Pole 6 Pole 8 Pole

Enclosed Open Enclosed Open Enclosed Open Enclosed Open

1 81.5 81.5 88.5 88.5 86.5 86.5 80.0 80.0

1.5 87.5 87.5 89.5 89.5 90.2 89.5 82.5 81.5

2 88.5 88.5 89.5 89.5 91.0 90.2 87.5 89.5

3 89.5 88.5 91.7 91.7 91.7 91.0 88.5 90.2

5 91.0 89.5 91.7 91.7 91.7 91.7 89.5 91.0

7.5 91.7 91.0 93.6 93.0 93.0 92.4 89.5 91.7

10 92.4 91.7 93.6 93.6 93.0 93.6 91.7 92.4

15 92.4 91.7 94.1 94.1 93.0 93.0 91.0 91.7

20 92.4 92.4 94.1 94.1 93.0 93.6 91.7 92.4

25 93.0 93.0 94.5 94.5 94.1 94.1 91.7 92.4

30 93.0 93.0 94.5 95.0 94.1 94.5 93.0 93.0

40 93.6 93.6 95.0 95.0 95.0 95.0 93.0 93.0

50 94.1 94.1 95.4 95.4 95.0 95.0 93.6 93.6

60 95.0 95.0 96.2 96.2 95.8 95.8 94.1 94.5

75 95.0 95.0 96.5 96.2 95.8 95.8 95.0 95.4

100 95.4 95.0 96.5 96.5 96.2 96.2 95.0 95.4

125 96.2 95.4 96.5 96.5 96.2 96.2 95.4 95.4

150 96.2 95.4 96.8 96.8 96.8 96.5 95.4 95.4

200 96.5 96.2 97.1 96.8 96.8 96.5 95.8 95.4

250 96.8 96.2 97.1 96.8 96.8 96.8 96.2 96.2

300 96.8 96.5 97.1 96.8 96.8 96.8 96.2 96.2

350 96.8 96.5 97.1 96.8 96.8 96.8 96.2 96.2

400 96.8 96.8 97.1 96.8 96.8 96.8 96.2 96.2

450 96.8 97.1 97.1 97.1 96.8 97.1 96.2 96.2

500 96.8 97.1 97.1 97.1 96.8 97.1 96.2 96.25A

- 22 Table 5

. 7 NEMA Design C Electric Motors at CSL 0

Horsepower Nominal Full Load Efficiency (%)

4 Pole 6 Pole 8 Pole

Enclosed Open Enclosed Open Enclosed Open

1 82.5 82.5 80.0 80.0 74.0 74.0

1.5 84.0 84.0 85.5 84.0 77.0 75.5

2 84.0 84.0 86.5 85.5 82.5 85.5

3 87.5 86.5 87.5 86.5 84.0 86.5

5 87.5 87.5 87.5 87.5 85.5 87.5

7.5 89.5 88.5 89.5 88.5 85.5 88.5

10 89.5 89.5 89.5 90.2 88.5 89.5

15 91.0 91.0 90.2 90.2 88.5 89.5

20 91.0 91.0 90.2 91.0 89.5 90.2

25 92.4 91.7 91.7 91.7 89.5 90.2

30 92.4 92.4 91.7 92.4 91.0 91.0

40 93.0 93.0 93.0 93.0 91.0 91.0

50 93.0 93.0 93.0 93.0 91.7 91.7

60 93.6 93.6 93.6 93.6 91.7 92.4

75 94.1 94.1 93.6 93.6 93.0 93.6

100 94.5 94.1 94.1 94.1 93.0 93.6

125 94.5 94.5 94.1 94.1 93.6 93.6

150 95.0 95.0 95.0 94.5 93.6 93.6

200 95.0 95.0 95.0 94.5 94.1 93.6

250

- - - - - -

300

- - - - - -

350

- - - - - -

400

- - - - - -

450

- - - - - -

500

- - - - - -5A

- 23 Table 5

. 8 NEMA Design C Electric Motors at CSL 1

Horsepower Nominal Full Load Efficiency (%)

4 Pole 6 Pole 8 Pole

Enclosed Open Enclosed Open Enclosed Open

1 85.5 85.5 82.5 82.5 77.0 77.0

1.5 86.5 86.5 87.5 86.5 80.0 78.5

2 86.5 86.5 88.5 87.5 85.5 87.5

3 89.5 88.5 89.5 88.5 86.5 88.5

5 89.5 89.5 89.5 89.5 87.5 89.5

7.5 91.0 90.2 91.0 90.2 87.5 90.2

10 91.0 91.0 91.0 91.7 90.2 91.0

15 92.4 92.4 91.7 91.7 90.2 91.0

20 92.4 92.4 91.7 92.4 91.0 91.7

25 93.6 93.0 93.0 93.0 91.0 91.7

30 93.6 93.6 93.0 93.6 92.4 92.4

40 94.1 94.1 94.1 94.1 92.4 92.4

50 94.1 94.1 94.1 94.1 93.0 93.0

60 94.5 94.5 94.5 94.5 93.0 93.6

75 95.0 95.0 94.5 94.5 94.1 94.5

100 95.4 95.0 95.0 95.0 94.1 94.5

125 95.4 95.4 95.0 95.0 94.5 94.5

150 95.8 95.8 95.8 95.4 94.5 94.5

200 95.8 95.8 95.8 95.4 95.0 94.5

250

- - - - - -

300

- - - - - -

350

- - - - - -

400

- - - - - -

450

- - - - - -

500

- - - - - -5A

- 24 Table 5

. 9 NEMA Design C Electric Motors at CSL 2

Horsepower Nominal Full Load Efficiency (%)

4 Pole 6 Pole 8 Pole

Enclosed Open Enclosed Open Enclosed Open

1 86.5 86.5 84.0 84.0 78.5 78.5

1.5 87.5 87.5 88.5 87.5 81.5 80.0

2 87.5 87.5 89.5 88.5 86.5 88.5

3 90.2 89.5 90.2 89.5 87.5 89.5

5 90.2 90.2 90.2 90.2 88.5 90.2

7.5 91.7 91.0 91.7 91.0 88.5 91.0

10 91.7 91.7 91.7 92.4 91.0 91.7

15 93.0 93.0 92.4 92.4 91.0 91.7

20 93.0 93.0 92.4 93.0 91.7 92.4

25 94.1 93.6 93.6 93.6 91.7 92.4

30 94.1 94.1 93.6 94.1 93.0 93.0

40 94.5 94.5 94.5 94.5 93.0 93.0

50 94.5 94.5 94.5 94.5 93.6 93.6

60 95.0 95.0 95.0 95.0 93.6 94.1

75 95.4 95.4 95.0 95.0 94.5 95.0

100 95.8 95.4 95.4 95.4 94.5 95.0

125 95.8 95.8 95.4 95.4 95.0 95.0

150 96.2 96.2 96.2 95.8 95.0 95.0

200 96.2 96.2 96.2 95.8 95.4 95.0

250

- - - - - -

300

- - - - - -

350

- - - - - -

400

- - - - - -

450

- - - - - -

500

- - - - - -5A

- 25 Table 5

. 10 NEMA Design C Electric Motors at CSL 3

Horsepower Nominal Full Load Efficiency (%)

4 Pole 6 Pole 8 Pole

Enclosed Open Enclosed Open Enclosed Open

1 87.5 87.5 85.5 85.5 80.0 80.0

1.5 88.5 88.5 89.5 88.5 82.5 81.5

2 88.5 88.5 90.2 89.5 87.5 89.5

3 91.0 90.2 91.0 90.2 88.5 90.2

5 91.0 91.0 91.0 91.0 89.5 91.0

7.5 92.4 91.7 92.4 91.7 89.5 91.7

10 92.4 92.4 92.4 93.0 91.7 92.4

15 93.6 93.6 93.0 93.0 91.7 92.4

20 93.6 93.6 93.0 93.6 92.4 93.0

25 94.5 94.1 94.1 94.1 92.4 93.0

30 94.5 94.5 94.1 94.5 93.6 93.6

40 95.0 95.0 95.0 95.0 93.6 93.6

50 95.0 95.0 95.0 95.0 94.1 94.1

60 95.4 95.4 95.4 95.4 94.1 94.5

75 95.8 95.8 95.4 95.4 95.0 95.4

100 96.2 95.8 95.8 95.8 95.0 95.4

125 96.2 96.2 95.8 95.8 95.4 95.4

150 96.5 96.5 96.5 96.2 95.4 95.4

200 96.5 96.5 96.5 96.2 95.8 95.4

250

- - - - - -

300

- - - - - -

350

- - - - - -

400

- - - - - -

450

- - - - - -

500

- - - - - -

5A.6 MATERIAL PRICING ASS UMPTIONS

DOE gathered material pricing information from numerous sources , including subject

matter experts (SMEs), manufacturers, internal material pricing databases developed from

research on other rulemakings , the U.S. Census Bureau’s Producer Price Index, the London

Metal Exchange and the Commodity Exchange, Inc. DOE used a 2011 doll ar pricing for a

majority of the materials, but for copper wire and cast copper prices DOE used a five

- year

average dating from 2007

- 2011.5A

- 26 5A.6.1 Copper Wire Pricing

DOE used a five

- year average price for copper due to the large price fluctuations in

copper w ire and copper used for casting. The five

- year average copper pricings are displayed in

Table 6

. 1 . DOE used a constant price for all wire gauges due to the small pricing differences

between the different wire gauges.

Table 6

. 1 Copper Material Pricing

Material Type 5 Year Average Year

Cu Wire ($/lb) 2011

- 2007 2011 2010 2009 2008 2007

Cu Wire, Gauge 14 & 14.5 $4.35 $4.00 $3.49 $2.45 $3.39 $3.39

Cu Wire, Gauge 15 & 15.5 $4.35 $4.00 $3.49 $2.45 $3.39 $3.39

Cu Wire, Gauge 16 & 16.5 $4.35 $4.00 $3.49 $2.45 $3.39 $3.39

Cu Wire, Gauge 17 & 17.5 $4.35 $4.00 $3.49 $2.45 $3.39 $3.39

Cu Wire, Gauge 18 & 18.5 $4.35 $4.00 $3.49 $2.45 $3.39 $3.39

Cu Wire, Gauge 19 , 19.5, 20 &20.5 $4.35 $4.00 $3.49 $2.45 $3.39 $3.39

Casting Materials ($/lb)

Casting Materials

- Copper $3.35 $4.00 $3.49 $2.45 $3.39 $3.39

5A.6.2 2011 Material Pricing

DOE used a constant 2011$ pricing for the remaining materials which include electrical

steels, aluminum for casting, cast iron, and hot rolled steel. These price assumptions are

displayed in Table 6

. 2

.5A

- 27 Table 6

. 2 Material Pricing in Constant 2011$

Motor Frame/End Bell Material ($/lb)

Frame Material

- Cast Iron 20k

- 30k psi $0.60

Frame Material

- Steel Fabrication $0.47

Frame Material

- Aluminum (extruded or cast) $1.30

Casting Materials ($/lb)

Casting Materials

- Aluminum $1.30

Core Steels

- ASTM #, Thickness, Processing ($/lb)

26M12, .0185", fully/semi

- processed $1.10

26M15, .0185", fully/semi

- processed $1.05

26M19, .0185", fully/semi

- processed $1.02

26M22, .0185", fully/semi

- processed $0.95

26M27, .0185", fully/semi

- processed $0.89

26M36, .0185", fully/semi

- processed $0.80

26M47, .0185", fully/semi

- processed $0.78

26M56, .0185", fully/semi

- processed $0.73

Other AISI Size or Thickness

Rotor Shaft ($/lb)

Hot Rolled AISI #1040 Series $0.52

Bearings ($/each)

Front Bearing, 5

- HP $10.11

Back Bearing, 5

- HP $5.66

Front Bearing, 30

- HP $31.30

Back Bearing, 30

- HP $14.39

Front Bearing, 50

- HP $49.35

Back Bearing, 50

- HP $25.29

Front Bearing, 75

- HP $67.41

Back Bearing, 75

- HP $36.19

5A.7 LABOR TIME AND COST ASSUMPTIONS

DOE estimated labor hours for each CSL of each representative unit. DOE requested

information from manufacturers concerning labor time associated with certain electric motor

horsepower ratings. A summary of these labor time estimates is displayed in Table 7

. 1 . Due to

the limited manufacturer feedback, DOE relied primarily on SME input to derive the time

requirements to build the representative units. For the purchas ed representative units (CSL 0

- 3

for the NEMA Design B motors and CSL 0 for the NEMA Design C motors) DOE relied on

visual inspection by motor industry experts to determine if a motor was machine or ha nd wound.

All motors above CSL 3 were considered hand wound, regardless of slot fill pe rcentage.

Approximate slot fill percentages are displayed in Table 7

. 2

.5A

- 28 Table 7

. 1 Labor Hour Assumpti ons by Candidate Standard Level ( CSL )

APPENDIX 5A. Labor Hours

HP Rating CSL 0 CSL 1 CSL 2 CSL 3 CSL 4 CSL 5

5, Design B 1.25 1.31 1.38 1.45 3.50* 3.68*

30, Design B 2.00 2.10 2.21 2.32 6.00*

- 75, Design B 3.50 3.68 3.86 4.06 9.00* 9.45*

5, Design C 1.25 1.31 3.50* 3.68*

- - 50, Design C 2.75 2.89 7.50* 7.88*

- - * Based on slot fill measurements, DOE assumed a hand

- wound labor hour amount for these

motors

Table 7

. 2 Slot Fill Percentages by Candidate Standard Level ( CSL )

APPENDIX 5A. Approximate Slot Fill

HP Rating CSL 0 CSL 1 CSL 2 CSL 3 CSL 4 CSL 5

5, Design B 43.5% 57.2% 70.0% 68.6% 82.4% 85.2%

30, Design B 48.4% 84.0% 70.0% 70.0% 83.2%

- 75, Design B 48.0% 44.5% 70.0% 70.0% 85.1% 83.4%

5, Design C 67.9% 79.9% 83.9% 82.9%

- - 50, Design C 79.6% 74.8% 85.3% 81.3%

- -