NEMA Super Premium motors, severe-duty enclosures, 20% energy savings

NEMA Super Premium (IE4) motor insights

• A severe duty motor is available meeting NEMA Super Premium (IE4) efficiency.
• Motor losses fall as much as 20% for significant energy savings; up to 60% savings is available with a variable-speed drive.
• Other benefits of the severe duty NEMA Super Premium efficiency motors include extended motor life, reduced maintenance and increased uptime.

ABB’s expanded Baldor-Reliance SP4 [NEMA Super Premium (IE4)] technology has expanded to severe-duty enclosures (Figure 1), advancing technology and maximizing energy efficiency in the line, as announced Aug. 12 and shared with Control Engineering in an Aug. 7 online new product discussion with Brandon Canclini, ABB NEMA Motors Division global product manager.

Figure 1: ABB’s expanded Baldor-Reliance SP4 [NEMA Super Premium (IE4)] technology has expanded to severe-duty enclosures, advancing technology and maximizing energy efficiency in the line, as announced Aug. 12. Courtesy: ABB NEMA Motors Division

The development of the new cast-iron totally enclosed fan cooled (TEFC) severe duty motor marks the second phase of ABB’s SP4 technology launch. The design suits applications in hazardous environments with certifications for Division 2 and Class I Groups A, B, C, D, as well as Class II Groups F and G, appropriate for areas with explosive gases and combustible dust. The model has an IP55 rating, ensuring protection against dust and water spray, for harsh and dirty conditions. Two previously introduced ABB SP4 models are rolled steel open drip proof and TEFC motors.

The SP4 product line builds on the ABB AC induction motors offerings with a range of durable motors to meet diverse, severe-duty applications. The motors are compatible with pumps, fans, compressors and conveyors and could be used in all industries. The new cast-iron motors cover a power range of 25 to 300 HP, and the rolled-steel SP4 models, launched earlier this year, are available in ¼ to 20 HP.

Figure 2: ABB revised its Energy Savings Calculator to include the new motors. Find motor payback time, get an energy consumption report and quantify sustainability and carbon-dioxide savings, explained Brandon Canclini, ABB NEMA Motors Division global product manager. Courtesy: ABB NEMA Motors Division

“Reducing electricity consumption benefits communities, businesses and the environment,” Canclini said. “The addition of the ABB Baldor-Reliance SP4 motors doubles down on our commitment to advancing our motor technology and maximizing energy savings.”

Motor energy savings with NEMA Super Premium (IE4) efficiency

More than 80% of industrial electric motors run direct-on-line (DOL), independent of a drive. As a standalone DOL unit, SP4 achieves NEMA Super Premium (IE4) efficiency. Highly efficient motors become even more efficient when paired with an ABB variable speed drive for increases up to 60% savings, he said. SP4 motors run cooler, reducing heat-based energy losses and extending bearing and other component life. Reducing energy losses leads to lower electrical energy consumption, which lowers operating costs and total cost of ownership.

Available in 2, 4 or 6-pole configurations, SP4 can seamlessly replace existing units to deliver efficiency upgrades for current applications. All SP4 models come with a standard 48-month warranty and are designed to easily replace existing NEMA motors, in simple direct-start setups or more advanced variable-speed operations.

SP4 motors comply with current U.S. Department of Energy efficiency standards and anticipated Medium Electric Motor (MEM) regulations, which take effect June 1, 2027. These regulations require motors up to 100 horsepower to meet NEMA Premium efficiency and motors between 100 and 250 horsepower to achieve NEMA Super Premium efficiency (Figure 3).

Figure 3: Are you ready for savings? SP4 motors comply with current U.S. Department of Energy efficiency standards and anticipated Medium Electric Motor (MEM) regulations, which take effect June 1, 2027. These regulations require motors up to 100 horsepower to meet NEMA Premium efficiency and motors between 100 and 250 horsepower to achieve NEMA Super Premium efficiency, said Brandon Canclini, ABB NEMA Motors Division global product manager. Courtesy: ABB NEMA Motors Division

Details on SP4 motors, NEMA Super Premium (IE4), motor efficiency calculator

Canclini provided more information about the motors in online comments.

• Electric motors provide opportunities to save energy while reducing costs and emissions helping address climate change, population growth and urbanization challenges.

• Electric motors consume 45% of electricity globally; by 2040 number of electric motors are expected to double. Estimated 10% energy savings would result if the more than 300 million industrial electric motor-driven systems in operation were replaced with optimized, high-efficiency equipment.

• From 2018 to 2024, average U.S. retail cost of electricity has increased 18%, according to the U.S. Energy Information Administration, and European Union countries pay twice the rate as in the U.S.

• Motors are a large source of potential savings for companies; more than 97% the total cost of ownership (TCO) for motors is the energy. Example: Replacing a NEMA Premium motor, Canclini said, with an ABB SP4 NEMA Super Premium motor result on return on investment on a 10 HP motor can be two years or less. Annual cost savings can be $276 with 3% (1 ton) of CO₂ reduction (Figure 4).

• The Database of State Incentives and Efficiency (DSIRE) [https://Dsireusa.org] provides information about 163 local utility programs; search by ZIP code, equipment type and other parameters.

• The 93% efficiency of the motors mean that for every $1000 in energy input, $70 is lost in heat and $930 in energy output is provided. By running 10 degrees C cooler, ABB SP4 motor insulation life doubles, and life of bearings and motor increases.

• ABB SP4 motors have a 4-year warranty.

• Revised ABB SP4 nameplates are larger, easier to read and contain more information, including a QR Code, serial number barcode and connection diagrams.

• ABB revised its Energy Savings Calculator to include the new motors. Advantages of use include finding payback time, an energy consumption report and ability to quantify sustainability and carbon-dioxide savings with increasing transitions to electrical motion.

• ABB Motion’s motors and drives are said to contribute to energy-efficient, decarbonizing and circular solutions (use of recycle materials: steel, copper and aluminum) for customers, industries and societies.

• 90% of available products comply with the Buy American Act.

Figure 4: For example, replacing a NEMA Premium motor, Canclini said, with an ABB SP4 NEMA Super Premium motor result on return on investment on a 10 HP motor can be two years or less. Annual cost savings can be $276 with 3% (1 ton) of CO2 reduction, said Brandon Canclini, ABB NEMA Motors Division global product manager. Courtesy: ABB NEMA Motors Division

During the online ABB SP4 motor introduction, ABB’s Terry Bell, global platform manager, said other motor design capabilities are available in ABB Baldor-Reliance custom built motors, such as for explosion-proof applications.

Sustainability benefits of electrification include and extend beyond energy efficiency, as an Aug. 1 Control Engineering article demonstrates: “How to meet sustainability goals, part 2: The drive for industrial decarbonization.” Converting carbon-intensive industrial applications helps meet decarbonization goals. The article addresses renewable energy, electrification, emerging application and energy efficiency.

Learn more from ABB about motors and motion control at https://go.abb/motion.

Edited by Mark T. Hoske, editor-in-chief, Control Engineering, WTWH Media, mhoske@wtwhmedia.com.

KEYWORDS

NEMA Super Premium (IE4) Motors, severe duty motor

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