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If you have purchased an IE5 ultra premium motor or are planning to, you have made the right decision; however, turning the high efficiency figures on the nameplate into reality on site depends as much on correctly integrating the motor into your installation and drive as it does on ordering it. The vast majority of IE5 synchronous reluctance motors do not run direct-on-line (DOL); they must always be commissioned as a package together with a variable frequency drive (VFD). For this reason, the wrong drive selection, an incorrect parameter, an incompatible cable, or an overlooked mechanical alignment will both reduce efficiency and shorten motor life. As HEM Motor, with our identity as both manufacturer and supplier, this guide compiles the checklist that a buyer procuring an IE5 motor should follow before and during commissioning from a commercial perspective: the goal is to capture the full efficiency you purchased on site and to order the correct package at the quotation stage.
Why Should an IE5 Motor Be Ordered Together With a Drive?
The on-site realization of the IE5 efficiency class comes in most applications via synchronous reluctance (SynRM) technology, and these motors cannot establish starting torque and synchronous speed on their own. In other words, you cannot buy the motor alone and connect it to an old contactor panel; the right decision is to procure the motor and drive as a compatible package. The drive is the component that places the motor's efficiency curve at the correct point; therefore, when collecting your quotes, we recommend evaluating the motor and drive not separately but as a set whose warranty and parameter compatibility are provided together. Our article on why an IE5 synchronous reluctance motor does not run without a drive, package selection and cost explains the package logic from a procurement standpoint.
The fact that they do not run without a drive also reveals the difference between an IE5 motor and a classic asynchronous motor. In asynchronous motors the drive is often optional; in IE5 SynRM motors the drive is an inseparable part of the motor. This difference directly affects both the purchase budget and the commissioning procedure.
Correct Drive Selection: Current, Control Mode and Motor Profile
When sizing the drive, it is essential to select based on the motor's rated current rather than its rated power; the current profile of SynRM motors may differ from an equivalent asynchronous motor. The drive must support the synchronous reluctance/SynRM control mode. Some general-purpose drives offer only asynchronous (IM) and permanent magnet (PM) profiles; a drive without a SynRM profile cannot carry the IE5 motor's efficiency to its nameplate value. We addressed the importance of the PM versus SynRM distinction in our article on the difference between IE5 synchronous reluctance and permanent magnet (PM) motors; be sure to confirm this distinction when selecting the drive parameter library.
Parameter Entry: Accurate Transfer From Nameplate to Drive
The most critical step of commissioning is entering the motor nameplate values into the drive completely: rated power (kW), rated voltage, rated frequency, rated current, rated speed and number of poles. For SynRM motors, running the drive's automatic motor identification (auto-tune) routine is additionally recommended; this routine introduces the motor model to the drive's control algorithm. We explained nameplate reading step by step from a purchasing and commissioning perspective in our article on reading the motor nameplate: kW, speed, cosφ and efficiency; the same discipline applies to IE5 motors. A single incorrectly entered parameter causes the motor to run at lower-than-expected efficiency or to overheat.
Installation and Cabling: Insulation, dV/dt and Grounding
As with every drive-fed motor, in IE5 motors the high-frequency switching at the drive output creates additional stress on the motor cable and winding insulation. Over long cable distances, dV/dt voltage spikes can damage the winding; therefore, using shielded motor cable, evaluating a dV/dt or sine filter according to cable length, and keeping the distance between drive and motor within the drive manufacturer's limits are important. All models in our efficient electric motors range are produced with class F insulation and IP55 protection; however, in drive-fed operation the installation side must also comply with the rules to preserve insulation life.
Grounding is critical in drive-fed systems both for safety and for bearing health. High-frequency leakage currents can pass through the bearings in improperly grounded systems and cause premature failure. A low-impedance grounding connection between the motor body and the drive, terminating the shield braid at both ends, and where necessary evaluating insulated bearings/shaft grounding rings should be part of your commissioning checklist. We compiled the root causes of premature failure in our article on the electric motor lifespan and 7 causes of early failure; in drive-fed systems, grounding is the most effective way to prevent these causes.
Mechanical Alignment and Mounting Type Compatibility
When migrating to an IE5 motor, most buyers expect the same IEC frame in place of the old motor; however, the mounting type (B3 foot-mounted, B5/B14 flange, B35 combined), shaft diameter and key dimensions must be confirmed. In coupled connections, axial and angular alignment, and in belt-pulley connections, tension adjustment, directly affect vibration and bearing life. You can review mounting type selection on our electric motor mounting types page and mechanical compatibility in our article on mechanical compatibility when migrating to an IE4 motor: frame, foot and shaft; the same checks apply to IE5. A misaligned motor, however efficient, produces vibration and noise on site.
First Start-Up Checklist
The practical checks to follow before the first energization are: exact match of drive parameters with the nameplate; confirmation of the motor winding insulation resistance with a megger (especially to check for moisture in a motor stored for a long time); verification of phase sequence and rotation direction; clearance of the cooling fan and air channels; measurement of body grounding; and observation of vibration and temperature under no-load/graduated load. You can find winding insulation resistance measurement in our article on insulation resistance and megger testing in asynchronous motors; and rotation direction and phase sequence checks in our article on motor rotation direction and phase sequence. If you want temperature monitoring in a drive-fed system with PT100/PTC, our article on motor winding temperature monitoring: PT100 and PTC thermistor clarifies which sensor option to request when ordering.
Common Drive-Side Mistakes and Efficiency Loss
Many plants that bring an IE5 motor on site, when they notice the motor does not reach the nameplate efficiency, find that the problem lies not in the motor but in the drive settings. The most common mistake is leaving the drive in scalar (V/f) mode; a synchronous reluctance motor cannot produce torque without a vector or SynRM-specific control algorithm, and its efficiency drops. The second common mistake is leaving the switching frequency at its default value; a switching frequency that is too low causes torque ripple and noise, while one that is too high creates additional losses in the drive. The third mistake is not setting the ramp times (acceleration/deceleration) according to the application; a short ramp on high-inertia loads triggers an overcurrent fault in the drive. Getting these three settings right directly affects the return on the IE5 investment.
Another important point is evaluating the drive's need for energy recovery and a braking resistor. In quadratic-torque applications such as fans and pumps, a braking resistor is often not required; however, in conveyor, hoist and high-inertia shaft applications, the regenerative energy produced during deceleration may require a braking resistor or a regeneration unit. Clarifying which drive hardware is needed for which load type at the quotation stage ensures both correct drive sizing and a smooth commissioning. We addressed the fundamental logic of frequency drive selection in our article on variable frequency drive (VFD) with asynchronous motors; in IE5 motors this selection is not an option but a requirement.
From Warehouse to Site: Commissioning a Stored IE5 Motor
A significant portion of project motors wait in the warehouse for weeks or even months before installation. The winding insulation of a motor stored in a humid or temperature-fluctuating environment may have absorbed moisture even without any visible damage. Therefore, we recommend always measuring the winding insulation resistance with a megger before connecting the IE5 motor to the drive; if a low resistance value is read, drying the motor is mandatory before energization. You can find moisture control in stored and warehouse motors, along with polarization index (PI) and DAR interpretation, in our article on insulation resistance and megger testing in asynchronous motors. If this step is skipped, the winding may be damaged at first energization and warranty coverage becomes disputable.
Mechanical inspection before commissioning is at least as important as electrical inspection. Confirm free rotation by turning the shaft by hand; a motor that took an impact during transport may have a strained bearing. Make sure the cooling fan cover and air intake grilles are clear, that the lifting eyebolt on the body has been removed after transport, and that the terminal box gasket is in place. These simple checks ensure that the IP55 protection class is preserved on site and that the motor operates in line with its design life from the first day.
Protecting the Return on Your IE5 Investment
The fundamental rationale for migrating to an IE5 motor is energy saving and low operating cost; however, this gain is preserved only through correct commissioning. The wrong drive mode, an incorrect parameter, or inadequate grounding erodes the nameplate efficiency advantage on site. You can examine whether the efficiency difference between IE5 and IE4 justifies the investment in our article IE5 or IE4? Does the efficiency difference justify the investment?; and in which application migrating to IE5 makes sense in our IE5 ultra premium electric motors migration guide. When you commission the correct package with the correct parameters and correct installation, you capture the low-loss advantage of the IE5 motor for many years.
As HEM Motor, across our entire product range accessible from our home page, we engineer motors together with suitable drive and connection options. To clarify the supply process from stock status to delivery time, our article on premium efficient motor supply: stock, delivery time and project planning will also be a useful guide.
Frequently Asked Questions
Does an IE5 motor run direct-on-line without a drive?
No. Synchronous reluctance (SynRM) motors, the common technology of the IE5 efficiency class, do not run direct-on-line (DOL) because they cannot establish starting torque and synchronous speed on their own; they must always be commissioned together with a variable frequency drive that supports the SynRM control mode. For this reason, we recommend ordering the motor not alone but as a package compatible with the drive. Contact us at the quotation stage for the package logic and cost items.
Will my existing drive work with an IE5 motor?
Whether your existing drive works with an IE5 motor depends on whether the drive supports the synchronous reluctance/SynRM motor profile and on its current capacity. A drive offering only the asynchronous (IM) profile cannot carry the IE5 motor's efficiency to its nameplate value. If you share the drive model information and motor rated values with us, we will evaluate compatibility together and, if necessary, add a compatible drive to our quote.
Which tests should I perform before commissioning?
Before energization, verify the exact match of drive parameters with the motor nameplate, measure winding insulation resistance with a megger (especially for moisture in a stored motor), check phase sequence and rotation direction, measure body grounding, confirm clearance of cooling channels, and perform the first start under graduated load with vibration/temperature observation. This checklist ensures you capture the full efficiency you purchased on site.
Get a Quote
Contact the HEM Motor expert team to procure your IE5 ultra premium motor together with the correct drive, correct mounting type and commissioning support. We engineer the motor and drive as a compatible package with class F insulation and IP55 protection standards. Call us now at +90 (532) 345 49 86 or request a quote via our contact page.
