LV Titanium VSM delivers IE5 Ultra-Premium efficiency in a compact design

(See ABB at Machine Building South, 8 July 2026, on stand 64)

Energy Efficiency 2025, the IEA's primary annual analysis on global energy efficiency developments, highlights that industrial electric motor systems account for about 60% of global industrial electricity demand and ~25% of all global electricity use. It also raises the issue of aging motor stock: Over half of all industrial motors in use today are more than ten years old and are generally less efficient than newer models.

Replacing the worst-performing 10% of global motors with new IE3/IE4 motors could save as much energy annually as Denmark consumes: around 30 TWh. And the potential savings become even greater when higher-efficiency motors rated at IE5 and above are installed.

It is against this background that ABB is focused on boosting the energy efficiency of electric motors as an integral element of our Engineered to Outrun' ethos. And while there are significant efficiency gains to be reaped from upgrading a motor, still greater energy savings are achievable when a high-efficiency motor is used in combination with a variable speed drive (VSD). In contrast, fixed speed, direct-on-line (DOL) motors run at full speed with process flow typically regulated by mechanical means such as valves. This method of control is like driving a car with one foot fully on the accelerator and the other pumping the brake to adjust the speed.

Adding a VSD to a pump, fan or compressor motor enables its speed to be matched precisely to the required output. This will typically reduce power consumption by 25%, and in some applications the savings can be much larger.

While the business and environmental benefits of VSDs are tangible, their uptake by industry has progressed at rather a modest pace since they were first introduced 50 years ago. At ABB, we estimate that roughly 50% of industrial motors would benefit from being paired with a drive. But currently only around 26% of the world's industrial motors are equipped with one.

In collaboration with customers, we investigated how we could improve this situation and a clear message emerged. To boost the industrial uptake of speed-controlled technology we had to make it as easy to install and operate as possible, especially in cases where using a separate drive can be challenging.

Our answer is the LV Titanium Variable Speed Motor (VSM) platform. This provides a simple, straightforward method to achieve IE5 Ultra-Premium efficiency in a wide range of industrial applications. It promises to be a game-changer, especially as a replacement for existing DOL induction motors, where it offers an easy upgrade path to a VSD-driven motor with a fast return on investment (ROI).

A streamlined motor and drive concept

Our key design aim was to achieve far more than simply bolting a drive on to a motor. So right from the start, the VSM was engineered as a streamlined concept, with an advanced drive module purpose-designed for optimal performance with a permanent magnet (PM) motor. PM technology is ideal for a VSM as it delivers high power density and high efficiency over the entire speed range. It also ensures a competitive route to an optimized total cost of ownership (TCO).

The result is a sleek, compact design, housed in a robust cast-iron frame, with the axial drive mounted on the end of the motor. This saves space and makes the VSM platform ideal for applications like both vertical and horizontal pumps, compressors and fans.

The LV Titanium platform offers several advantages during commissioning and installation. First of all, compact size and light weight makes it easier to handle and install the motor. Second, plug-and-play functionality means that the VSM significantly reduces the need for commissioning, as its motor and drive are commissioned and optimised to work together before leaving the factory. Furthermore, there is no requirement for the special cabling associated with separate drives, as the VSM is connected in the same way as a standalone DOL motor. This makes installation fast and easy, with no need for cabinets or electrical rooms.

The advantages of IE5 Ultra-Premium efficiency include rapid payback

The VSM already goes beyond current legislation by offering IE5 Ultra-Premium efficiency, a significant improvement over the IE4 required currently by the EU's Ecodesign Directive. When specifying a motor it is vital to look beyond the upfront investment and to consider the motor's TCO. Over a long lifetime - typically 25 years - the cost of the motor is far outweighed by the cost of the electricity to power it. For a VSM, the upfront cost will be around 2% of its TCO, maintenance accounts for 1% and the remaining 97% is spent on electricity.

An IE5 motor has 40% lower energy losses than the IE3 products that are in common use. Therefore, investing in IE5 rather than IE3 motors can have a very short payback time due to the energy savings. The highest system efficiency of IES5 is achieved according to IEC 61800-9-2 for the combined motor and drive package.

The savings on energy costs and carbon intensity that customers can achieve by switching to a VSM is illustrated by a typical 15 kW centrifugal pumping application.

Compared with a conventional, standalone fixed-speed IE3 DOL motor, the savings on the electricity bill over a 15-year lifetime, running 6000 hours a year at 80% power, will be well over Euro 121,000, with an anticipated ROI of just a few months. This is based on a typical energy cost for Europe of Euro 0.21/kWh. At the same time, there is a lifetime avoidance of 174,000 kg in CO2 emissions -that is equivalent to the emissions produced when driving 40 typical gasoline powered passenger vehicles for a year - based on the average European carbon intensity factor of 0.3 kg CO2/kWh.

The savings quoted here are for just one motor. Yet typical industrial facilities will have tens or even hundreds of this size of motor, and a large plant such as a paper mill can have thousands. So the global potential to cut costs and reduce emissions is enormous.

Achieving the most favourable operational profile

Thanks to their built-in drive, VSMs can produce the most favourable operational profile for the equipment and process. In pump applications, for example, the speed can be ramped up and down steadily to reduce starting currents and avoid mechanical stresses on the equipment and sudden pressure changes in pipework, that will help extend equipment lifespan.

Furthermore, several key safety features like safety torque off', over-temperature', overload', earth fault protection' and many more, are already integrated into the VSM.

A broad spectrum of speed and torque requirements

Thanks to its compact design and high power density, the VSM can be up to three frame sizes smaller than comparable induction motors. This makes it suitable for installations where space and weight are at a premium, both for new equipment designs and in some cases when replacing older, inefficient motors.

The first LV Titanium models were delivered in smaller sizes up to 7.5 kW. The scope has now expanded to cover frame sizes from 71 to 160, and power ratings from 1.1 up to 30 kW, with rated speeds up to 4500 rpm. This enables VSM technology to cover industrial sectors such as data centres, water treatment, food and beverage, HVAC and general machinery.

Currently, based on our industrial experience, we anticipate four main applications:

Pumps: with the axially mounted drive, the VSM is ideally suited for vertical pumping applications. It also offers a compact installation that delivers speeds up to 4500 rpm for optimized flow and energy saving.

Compressors: compact size offers a wide range of speed/torque capability to meet requirements under different operating conditions.

Material handling: low-speed, high-torque operation is possible, providing flexibility in operation of conveyors.

Data centres: Provides high efficiency as a replacement for current electrically commutated (EC) fans.

We have tested the VSM platform with customers, and one additional benefit that has been noted is its exceptionally quiet operation - just above ambient levels.

While the VSM is available as a stock item in standard configurations, it is a flexible platform that allows the customisation of features such as mounting arrangements and shaft end dimensions for the development of customer-specific solutions.

A new benchmark in performance and simplicity

Instead of a separate motor and drive, the LV Titanium VSM offers a 2-in-1 solution that combines an IE5 Ultra-Premium efficiency PM motor and drive into one compact unit. With its groundbreaking energy efficiency, versatility, robustness, and compact design, the VSM sets a new benchmark in performance and simplicity. The platform is poised to transform industrial operations worldwide by offering a forward-thinking solution that not only meets current industry demands, but also anticipates those of the future.