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Headquartered in Zurich, Switzerland, ABB is a Fortune 500 electrical equipment manufacturer and one of the world’s biggest suppliers of industrial motors. The company acquired U.S. manufacturer Baldor Electric in 2011. Baldor had acquired Reliance Electrical Company in 2007.
The company is in the middle of a multi-phase rollout of its SP4™ Super Premium motor technology, which promises energy efficiency gains and cooler operation. These motors are sold under the Baldor-Reliance® brand.
Driven by National Electrical Manufacturers Association (NEMA) and Department of Energy (DOE) motor efficiency regulations taking effect in 2027, ABB began developing SP4 technology in 2021. While the regulations apply only to 100-horsepower (hp) and higher motors, the company is creating a full range of these motors.
Full suite of new Baldor-Reliance SP4 motors.
Technical Innovations for Improved Motor Efficiency
Manufacturing motors with NEMA Super Premium efficiency (the equivalent to an IEC IE4 rating) required technical innovations. The SP4’s electrical grade steel is created with a new process. The motor’s stator core was redesigned with a longer iron stack, incorporating more iron to improve efficiency. Additional copper and increased active material in the rotor core further optimize energy conversion. These advances let SP4 motors convert electrical energy into mechanical energy while minimizing energy loss as heat. This results in up to 20% more efficient motors than previous models, reducing energy waste by the same margin.
An ABB Baldor-Reliance SP4 rolled steel motor.
The reduction of heat losses allows SP4 motors to run at lower operating temperatures, which extends their lifespans. The improved steel allows ABB to better control magnetic flux lines and limit losses, furthering efficiency gains. These motors are rated for an operating temperature of 104°F (40°C), the industry standard.
Thanks to the SP4’s lower operating temperature, ABB has improved the most common failure point of electric motors – the durability of their bearings. As a result, customers benefit from the motor’s extended overall lifespan. Reflecting this, ABB is offering these motors with a four-year warranty rather than the standard three-year warranty offered with other motor types.
“The 20% reduction in losses is a huge benefit for our customers. SP4 motors comply with upcoming regulations, which is another benefit. Also, they offer cooler operation for extended life. That's going to play into the added value our products give to our customers,” said Brandon Canclini, NEMA Motors Division Global Product Manager. “We increased our warranty period, going from a three-year warranty to a four-year warranty. So, I think it makes for an attractive package.”
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Brandon Canclini, NEMA Motors Division Global Product Manager.
Original equipment manufacturers (OEMs) will appreciate that these motors offer drop-in replacement with the same sizing and connection ports as previous models.
“For already-existing applications, if a motor goes down, we want to be able to give the market an opportunity to replace that product with a higher efficiency product. Customers can easily find a product within our offerings that will fit inside their existing application,” said Canclini.
Energy Savings for OEM Equipment
ABB is releasing these motors in a multi-phase launch. The first phase began in early 2024 with ¼ to 20-hp rolled steel in 2, 4 and 6-pole configurations. Customers can choose from totally enclosed non-ventilated (TENV) or totally enclosed fan cooled (TEFC) models. In June 2024, the company released these motors with severe duty enclosures, which include 25 to 300-hp models. These TEFC models are meant for hazardous environments. Insulation is Class F, with Class H as an option. Future rollouts will bring this technology to additional products.
SP4 motors can be paired with variable-speed drives for even greater efficiency and cost savings. Affinity laws show that during peak operation, power used to drive fans and pumps increases exponentially, not linearly. Reducing speed during low-use times greatly reduces the power consumed. An energy savings calculator on the company site (https://nema-energysave.us.abb.com) lets prospective buyers know what kind of savings to expect.
An ABB Baldor-Reliance SP4 cast-iron severe-duty motor.
Asked about the benefits to air compressors, Canclini said, “SP4 motors provide the high efficiency and reliability required for air compressors which operate under demanding and variable-load conditions. The reduced energy losses and cooler operating temperatures mean a lower total cost of ownership for manufacturers. Additionally, the NEMA Super Premium efficiency level ensures compliance with stringent energy regulations, making this a future-proof investment. Since this line only launched earlier this year, we haven’t yet compiled field results or document savings/case studies.”
For use in cooling towers and cooling water pumps, Canclini said, “For cooling tower and pump applications, SP4 motors offer unmatched reliability in handling variable load conditions and harsh environments. The motors’ cooler operation reduces the risk of overheating, which is crucial in temperature-sensitive cooling systems. Additionally, pairing these motors with ABB variable speed drives allows manufacturers to optimize energy use based on demand, achieving substantial energy and cost savings. Their durability and extended warranty give manufacturers confidence in their long-term performance.”
Finally, for aeration blowers, industrial blowers and vacuum pumps, Canclini said, “SP4 motors are designed to handle continuous, high-demand applications like those in blowers and vacuum pumps. Their ability to operate efficiently over extended periods reduces maintenance intervals and operational downtime. This is particularly valuable in aeration and industrial blower applications, where reliability and low operational costs are critical. The 20% reduction in motor loss directly translates to energy savings, while the improved cooling reduces heat-related wear, extending motor life.”
About ABB
ABB is a technology leader in electrification and automation, enabling a more sustainable and resource-efficient future. The company’s solutions connect engineering know-how and software to optimize how things are manufactured, moved, powered and operated. Building on more than 140 years of excellence, the company’s more than 105,000 employees are committed to driving innovations that accelerate industrial transformation. For more information, visit https://global.abb.
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