Download - Motor Present Ac i On
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MotorProMotorProTrainingTraining
TM
Gudnar RodriguezVenezuela & Caribbean Region Manager
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BASIC BASIC ELECTROMAGNETISM ELECTROMAGNETISM THEORYTHEORY
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Emerson Confidential
ElectromagnetismElectromagnetismElectromagnetism
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Emerson Confidential
..How magnetic field transmits torque?..How magnetic field transmits torque?..How magnetic field transmits torque?
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Emerson Confidential
ElectromagnetismElectromagnetismElectromagnetism
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Emerson Confidential
ElectromagnetismElectromagnetismElectromagnetism
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Emerson Confidential
Alternate CurrentsAlternate CurrentsAlternate Currents
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Emerson Confidential
Alternate CurrentsAlternate CurrentsAlternate Currents
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DC MOTORSDC MOTORS
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Emerson Confidential
Basic DC & Electromagnetism TheoryBasic DC & Electromagnetism TheoryBasic DC & Electromagnetism Theory
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Emerson Confidential
ArmatureArmatureArmature
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Emerson Confidential
ArmatureArmatureArmature
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Emerson Confidential
Fields and InterpolesFields and Fields and InterpolesInterpoles
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Emerson Confidential
Brushes and HoldersBrushes and HoldersBrushes and Holders
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Emerson Confidential
Exploded ViewExploded ViewExploded View
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Emerson Confidential
Final AssemblyFinal AssemblyFinal Assembly
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Emerson Confidential
Shunt and Series MotorsShunt and Series MotorsShunt and Series Motors
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Emerson Confidential
Compound Wound MotorsCompound Wound MotorsCompound Wound Motors
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Emerson Confidential
Permanent Magnet MotorsPermanent Magnet MotorsPermanent Magnet Motors
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Emerson Confidential
Dripproof Fully Guarded Self Ventilated (DPFG)DripproofDripproof Fully Guarded Self Ventilated Fully Guarded Self Ventilated (DPFG)(DPFG)
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Emerson Confidential
Dripproof Fully Guarded Blower Ventilated(DPBV)DripproofDripproof FullyFully GuardedGuarded BlowerBlower VentilatedVentilated(DPBV)(DPBV)
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Emerson Confidential
EnclosuresEnclosuresEnclosures
Dripproof SeparatelyVentilated (DPPV or DPSV)
Totally EnclosedSeparately Ventilated
(TEPV or TESV)
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Emerson Confidential
EnclosuresEnclosuresEnclosures
Totally Enclosed Non-Ventilated (TENV)
Totally Enclosed Air Over(TEAO)
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Emerson Confidential
Variable speed screw compressorsVariable speed screw compressorsVariable speed screw compressors
SR motor
Compressorunit
75kWmotor
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Emerson Confidential
Drax Power Ltd Fuel Blending SystemDraxDrax Power Ltd Power Ltd Fuel Blending SystemFuel Blending System
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Emerson Confidential
Picanol textile weaving loomsPicanolPicanol textile weaving loomstextile weaving looms
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Emerson Confidential
LeTourneau L1350 loader using 4 x B40 300kW SR traction motorsLeTourneauLeTourneau L1350 loader using L1350 loader using 4 x B40 300kW SR traction motors4 x B40 300kW SR traction motors
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INDUCTION MOTORSINDUCTION MOTORS
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Emerson Confidential
RotorRotorRotor
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Emerson Confidential
Stator FrameStator FrameStator Frame
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Emerson Confidential
Induction MotorInduction MotorInduction Motor
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A/C INDUCTION A/C INDUCTION MOTOR TYPESMOTOR TYPES
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Emerson Confidential
NOTE: These are NOT A/C Induction motors
UniversalUniversal Type Motor ExamplesType Motor Examples
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Emerson Confidential
A/C Induction Motor TypesA/C Induction Motor Types
Single PhaseShaded polePSCSplit-phase
Cap StartCap Start / Cap Run
Three-phase
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Emerson Confidential
Shaded PoleShaded PoleDescription: A single-phase motor with a main winding and shading coil (magnetic short circuit located around the air gap).
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Emerson Confidential
Principle Use: Direct drive shaft mounted fansAdvantages:
Low cost Multi-speed operation Slow acceleration rate No starting device required Requires little space
Disadvantages: Low efficiency, low starting torque High running current Slow acceleration rate Wide variation in speed with applied voltage Non-electrically reversible Requires air-over for cooling
Shaded PoleShaded Pole
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Emerson Confidential
P.S.CP.S.C (Permanent Split Capacitor)(Permanent Split Capacitor)Description: A single-phase motor with a main winding and an auxiliary winding connected in series with a capacitor.
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Emerson Confidential
Split PhaseSplit PhaseDESCRIPTION: A single-phase motor with a main winding and an auxiliary winding which is energized only during the starting operation.
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Emerson Confidential
PRINCIPLE USE: Belt-drive applicationsAdvantages: Moderate cost Moderate starting torque Moderate full-load current Easily reversed Constant speed with varying input voltage Good efficiency
Split PhaseSplit Phase
Disadvantages:Not easily adapted to multi-speedHigh starting currentHigh starting torqueRequires starting device
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Emerson Confidential
CAP STARTCAP START(Capacitor start, split phase)(Capacitor start, split phase)
Description: A single-phase motor with a main winding and an auxiliary winding which has a capacitor in series that is only energized during the starting operation.
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Emerson Confidential
Principle Use: Belt-driven applicationsAdvantages: Very high starting torque High accelerating torque Moderate starting current Moderate full-load current Dual voltage Easily reversed Good efficiency
Disadvantages:
CAP STARTCAP START(Capacitor start, split phase)(Capacitor start, split phase)
High costRequires starting deviceNot easily adapted to multi-speedVery high starting torqueHigh accelerating torque
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Emerson Confidential
ThreeThree--PhasePhase MotorsMotorsDescription: A motor with three separate windings, each connected to one leg of the power source.
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Principle Use: Commercial & Industrial applications
Advantages: Moderate cost No internal starting device required High efficiency High starting torque Easy to reverse Constant speed with varying input voltage
ThreeThree--PhasePhase MotorsMotors
Disadvantages:3-phase power source requiredHigh starting torqueModerate accelerating torqueNot easily adapted to multi-speed
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Emerson Confidential
MOTOR HP SPEED COST CHARACTERISTICS TYPICAL USES
TYPE RANGE RANGE
SHADED UP TO MULTI-SPEED VERY LOW Light duty for small loads Small fans and blowers Freezer blowers
POLE 1/2 HP 1050 Low efficiency, Hair dryers Small vent fans
1550 Air over design usually required. Unit heaters Small exhaust fans
3000 Single voltage, usually. Space heaters Window fans
Non-reversible Humidifiers Floor fans
Seed cleaners Portable evaporative coolers
PERMANANENT UP TO MULTI-SPEED LOW More efficiency and power Small mounted fans, blowers Animal confinement fans:
SPLIT 1 HP 825 Not for belt drive, as a rule Room AC and central AC: Poultry
CAPACITOR 1075 Single voltage and rotation, usually Condenser fans Hogs
1625 Solid state speed control may work Evaporator fans Cattle
3250 (Contact Technical Support) Furnance blowers Window fans
Unit heaters Door operators
SPLIT PHASE UP TO 850 MODERATE Low to medium starting torque Belted fans, blowers Oil burners
1.5 HP 1140 No capacitor needed for start-up AC fans, blowers Poultry feeders
1725 OK for belt drive Office machines Attic fans
3450 Single voltage, dual rotation, usually Small centrifugal pumps Furnance blowers
Variable speed control will not work Home appliances Small tools
Door operators Lathes
CAPACITOR 1/6 TO 850 MODERATE Capacitor provides hgih starting torque Compressors Barn cleaners
START 10 HP 1140 Heavy duty applications Conveyors Vacuum pumps
1725 Dual voltage, dual rotation, usually Pumps Manure pumps
3450 Augers Milk coolers
Machine tools Elevators
Grain stirrers Cattle feeders
Ventilation fans Drying fans
Food equipment Gear motors
3-PHASE 1/4 HP 850 MODERATE TO All applications using 3-phase power Compressors Barn cleaners
and UP 1140 HIGH Simple construction: Conveyors Vacuum pumps
1725 No capacitors, switches, or start windings Pumps Manure pumps
3450 Dependable Augers Milk coolers
Dual rotation Machine tools Elevators
Grain stirrers Cattle feeders
Ventilation fans Drying fans
Food equipment Gear motors
Motor Applications MatrixMotor Applications Matrix
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MotorMotorKnowKnow-- HowHow
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Emerson Confidential
MOST MOTORS USUALLY FAIL
BECAUSE OF
SYSTEM PROBLEMSSYSTEM PROBLEMS......
NOT
MANUFACTURING PROBLEMS !
MinerMiners Law #1s Law #1
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Emerson Confidential
100% STATIC HIPOT ( GROUND TEST)100% RUN TEST100% NO-LOAD WATTS100% NO-LOAD AMPS100% DYNAMIC HIPOT (GROUND TEST)100% NOISE TESTSAMPLE PLAN TESTS:
FULL-LOAD WATTS FULL-LOAD AMPS FULL-LOAD TORQUE LOCKED ROTOR TEST SPEED TORQUE CURVE TEST THERMOSTAT TRIP TEST
Manufacturing TestsManufacturing Tests
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Emerson Confidential
1. TYPE OF POWER (PHASE)2. MOTOR TYPE3. HORSEPOWER4. REVOLUTIONS PER MINUTE (RPM)5. THERMAL PROTECTION TYPE6. ENCLOSURE7. BEARING TYPE8. VOLTAGE9. MOUNTING
Motor FactsMotor Facts
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Emerson Confidential
C 04C
Example of Motor Name Plate:
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Emerson Confidential
Read This First!!Read This First!!
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Emerson Confidential
A/C Induction Motor TypesA/C Induction Motor Types
Single PhaseShaded polePSCSplit-phase
Cap StartCap Start / Cap Run
Three-phase
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Emerson Confidential
BELOW 1/2 HORSEPOWER...........115 VOLTS
1/2 AND ABOVE..............................230 VOLTS and ABOVE
Commonly, motors are connected at the factory as follows:
NOTE: Or as specified by the customer.
Rule of ThumbRule of Thumb
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Emerson Confidential
What is my RPM?What is my RPM?
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Emerson Confidential
# POLES NO LOAD RPM TYPICAL LOADED RPM2 3600 3000-3450
4 1800 1550-1750
6 1200 1075-1125
8 900 650-850
NOTE: 7200 DIVIDED BY NUMBER OF POLES=NO LOAD RPM (60 cycle)6000 DIVIDED BY NUMBER OF POLES=NO LOAD RPM (50 cycle)
Motor Poles vs. RPMMotor Poles vs. RPM
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Emerson Confidential
What are my RPMs?What are my RPMs?
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Emerson Confidential
What is my RPM?What is my RPM?
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Emerson Confidential
Rear End Front EndN-W
VU
F F BA
D
E E
C and J-Face Mounting Dimensions
Motor Dimensions for NEMA FramesMotor Dimensions for NEMA Frames
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Emerson Confidential
NEMA FRAME SIZE SHAFT HEIGHT
42 2 5/8 or 42/16
48 3 or 48/16
56 3 1/2 or 56/16
NEMA Frame SizesNEMA Frame Sizes
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Emerson Confidential
EXAMPLE:
Take the first two numbers, divide by four, and the result is the dimension from the center of the shaft to the base.
Example: 286 frame = 28 / 4 or 7 inches.
NOTE: Center line of shaft to base.
Shaft Height FormulaShaft Height FormulaNEMA Frame Sizes (starting at 143 frame)NEMA Frame Sizes (starting at 143 frame)
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C = FACE MOUNT H = HAS 2F DIMENSION LARGER THAN SAME FRAME
WITHOUT H SUFFIX J = FACE MOUNT TO FIT JET PUMP JM,JP = FACE MOUNT TO FIT CLOSE-COUPLED PUMPS K = HAS HUB FOR SUMP PUMP MOUNTING M = FLANGE MOUNT FOR OIL BURNER-5 1/2 RABBET DIA. N = FLANGE MOUNT FOR OIL BURNER - 6 3/8 RABBET DIA. T,TS = INTREGAL HP MOTOR DIMENSION NEMA STANDARDS
SET IN 1964 U = INTREGAL HP MOTOR DIMENSION NEMA STANDARD SET
IN 1953 Y = NON-STANDARD MOUNTING, SEE MANUFACTURES
DRAWING Z = NON-STANDARD SHAFT EXTENSION (N min. U dimension)
NEMA Frame NumberNEMA Frame Number(with Letter Designators)(with Letter Designators)
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FramesFramesFrames
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Emerson ConfidentialEmerson Confidential
H (mm)
IEC FramesIEC Frames
Example:Frame 355 S
H: 355 mm = 35,5 cmS= Short (distance between the base holes)
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Emerson Confidential
Frame Power RelationshipFrame Frame Power RelationshipPower Relationship
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Torque Speed CurveTorque Torque Speed CurveSpeed Curve
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Protector (Thermal)Protector (Thermal)A device assembled as an integral part of the motor which protects the motor against overheating due to an overload or failure to start. The words thermally protected on the nameplate indicate the motor is provided with a thermal protector.
AUTOMATIC RESET
A protector that resets automatically after it has cooled sufficiently.
MANUAL RESET
A protector that once tripped remains open until manually reset,usually by means of an external reset button. It cannot be reset until the protector has cooled sufficiently.
NONE
No thermal protection included in the motor
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Emerson Confidential
OP = OPENODP = OPEN DRIP-PROOFAO = AIR OVERTE = TOTALLY ENCLOSEDTEAO = TOTALLY ENCLOSED AIR OVERTENV = TOTALLY ENCLOSED NON-VENTEDTEFC = TOTALLY ENCLOSED FAN-COOLEDEXP-PRF = HAZARDOUS LOCATION
(EXPLOSION PROOF)
Enclosures (ENCL)Enclosures (ENCL)
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Emerson Confidential
Open (OP) Open Drip Proof (ODP)Totally EnclosedAir-Over (TEAO)
Totally EnclosedNon-Vented (TENV)
Totally EnclosedFan Cooled (TEFC)
Hazardous LocationTotally Enclosed
Fan Cooled(HAZ-LOC,TEFC)
Motor EnclosuresMotor Enclosures
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Emerson Confidential
Open Drip Proof (ODP)Open Drip Proof (ODP)Open Drip Proof (ODP)
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Emerson Confidential
Total Enclosed Fan Cooled (TEFC)Total Enclosed Fan Cooled (TEFC)Total Enclosed Fan Cooled (TEFC)
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Emerson Confidential
Hazardous Location (XP)Hazardous Location (XP)Hazardous Location (XP)
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Emerson ConfidentialRigid Base Mount
Resilient or Cradle BaseYoke Mount
Oil Burner Face Mount
C-Face with Base
C-Face Without Base
Pool or Jet Pump
Cradle Base Carbonator Pump
Motor MountingsMotor Mountings
C-Face Without Base
Rigid Base Mount
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Emerson ConfidentialEmerson Confidential
Medium Voltage MotorsMedium Voltage Motors
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Emerson ConfidentialEmerson Confidential
Vertical Motors (Solid and Hollow Shaft)Vertical Motors (Solid and Hollow Shaft)
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Emerson Confidential
115 VOLTS 230 VOLTSCOMMON WHITE PURPLEHIGH BLACK BLACKMED-HIGH YELLOW YELLOWMEDIUM BLUE BLUEMED-LOW ORANGE ORANGELOW RED REDCAPACITOR BROWN & BROWN & BROWN W/ WHITE BROWN W/ WHITE TRACER TRACER
NEMA Lead Color CodesNEMA Lead Color Codes
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Emerson Confidential
Typical MultiTypical Multi--Speed (1/2 HPSpeed (1/2 HP--6 Pole)6 Pole)No Load 1/2 HP Load 1/3 HP Load 1/4 HP
HIGH 1200 1075 1100 1125
MED 1200 1000 1075 1100
LOW 1200 900 1000 1075
Reminder:Actual RPM is determined by actual load!
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Note: Service Factor = Overload Capability
EXAMPLE:
1.35 Service Factor = 35% O.L. Capabilityor
HP Rating x Service Factor = Maximum HP
Example: .25 HP x 1.35 = .338 (1/3+)
Service FactorService Factor
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WORN EQUIPMENT
MARGINAL OEM APPLICATION
OCCASIONAL UNDER VOLTAGE
MODERATE HIGH AMBIENT
Common Usage For Service Factor MotorsCommon Usage For Service Factor Motors
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Emerson Confidential
z Prelubricated Bearings No further Lubrication Required
z Reoil Bearings SAE 20 Oil Continuous Duty : Every Year
Intermittent Duty : Every 2 Years
Occasional Duty : Every 5 Years
Motor LubricationMotor Lubrication
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Emerson Confidential
LOW VOLTAGE
OVER VOLTAGE
HIGH AMBIENT
REDUCED AIR FLOW
FOREIGN MATERIAL IN MOTOR
DIRTY FILTERS
APPLICATION OVERLOAD
MISAPPLICATION
Causes of HeatCauses of Heat
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Emerson Confidential
Causes of HeatCauses of Heat
Temperatures shown in C
Service Factor 1.00 1.15 and up Purpose Alarm Shutdown Alarm Shutdown
Temp. Rise Class A B F A B F A B F A B F Open Motors N.O. 95 118 140 106 132 150 106 132 150 118 140 160
Without N.C. 100 120 140 110 130 150 110 130 150 120 140 160Ducts: N.C. (R&T) 100 120 140 110 130 150 110 130 150 120 140 160
Open Motors N.O. 106 132 150 118 140 160 118 140 150 132 150 160With Ducts & N.C. 110 130 150 120 140 160 120 140 150 130 150 160TEFC Motors: N.C. (R&T) 110 130 150 120 140 160 120 140 150 130 150 160
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EfficiencyEfficiency LevelsLevels
78808284868890929496
3 5 7,5 10 15 20 25 30
Best in Market NEMA 12-10 Standard
E
F
F
I
C
I
E
N
C
Y
HORSEPOWER RATING
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Standard Efficiency vs PremiumStandard Efficiency vs Premium
zz EfficiencyEfficiency -------- 11--6% better6% betterzz Winding TemperatureWinding Temperature -------- lesslesszz Frame Temperature Frame Temperature -------- lesslesszz Starting CurrentStarting Current -------- slightly moreslightly morezz Starting TorqueStarting Torque -------- samesamezz FLAFLA -------- higherhigherzz Bearing Temperature.Bearing Temperature. -------- (8(8--15)15)C lessC lesszz WarrantyWarranty -------- 11--2 years more2 years more
Premium. Designed to improve the efficiency Premium. Designed to improve the efficiency without compromising the functioning or lifetimewithout compromising the functioning or lifetime
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Methods to Efficiency MeasurementMethods to Efficiency Measurement
Standard 7.5 HP 20 HPIEC 34-2 (International) 82.3% 89.4%BS-269 (British) 82.3% 89.4%JEC-37 (Japanese) 85.0% 90.4%IEEE 112 Method B (USA) 80.3% 86.9%
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CLASS A 105 DEG. C (221 DEG. F)
CLASS B 130 DEG. C (266 DEG. F)
CLASS F 155 DEG. C (311 DEG. F)
CLASS H 180 DEG. C (356 DEG. F)
TOTAL TEMPERATURE OF SYSTEM
( MAXIMUM ALLOWABLE OPERATING TEMPERATURE )
Insulation SystemsInsulation SystemsInsulation Systems
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PowerPowerPower
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Standard Horsepower RatingsStandard Horsepower RatingsStandard Horsepower Ratings
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Torque Power RelationshipTorque Torque Power RelationshipPower Relationship
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Emerson Confidential
Torque Power RelationshipTorque Torque Power RelationshipPower Relationship
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InrushInrushInrush
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1. Application2. Enclosure3. Mounting4. Bearing and seals5. Starting Method6. Operation Characteristics 7. Protection8. Enviroment
How to Select a Right Motor?How to Select a Right Motor?
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Emerson Confidential
Standard MotorsStandard MotorsStandard Motors
Less High
Price
HOSTILEDUTY(FCT)
UNIMOUNT(FUT)
PREMIUM EFF.CORRO-DUTY
(TCE)
841 PLUS(CE)
ROLLEDSTEEL
(FS)ODP
(FR, FD)
High
Performance
Low
Performance
O&G
P&P
Mining
Agriculture
Fans / Pumps / Compressors
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Starting MethodsStarting MethodsStarting Methods
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ACROSS THE LINE CONTACTOR STARTINGACROSS THE LINE ACROSS THE LINE CONTACTOR STARTINGCONTACTOR STARTING
Time (sec) (t)0
0%
100%
Full Voltage Start
600-1000% Current
Voltage
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Starting MethodsStarting MethodsStarting Methods
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Traditional Methods for Soft Starting Traditional Methods for Soft Starting
CURRENT
SPEED
0
600%
SOLIDSTATE STARTER
ACROSS LINE
AUTOTRANSFORMER
STAR -DELTA
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Where does the Soft Starters can be used?Where does the Soft Starters can be used?Where does the Soft Starters can be used?PumpingProblems:
Water Hammer
Back Pressure
Blown Valves
Dry Run
Solution: Pump Control Mode
Softstart
Ramp Down
Monitoring
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Emerson Confidential
Mining AggregateProblems:
High Inertia Limited Power Vibration During
Stop Overloading
Solution:Crusher Duty
Where does the Soft Starters can be used?Where does the Soft Starters can be used?Where does the Soft Starters can be used?
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Emerson Confidential
HVACProblems:
High Currents Near Full Speed
Incorrect Rotation Belt or Coupling Broken or
Jammed Clogged Filter or Closed
Damper
Solution: Pump Control Mode Softstart Ramp Down Monitoring
Where does the Soft Starters can be used?Where does the Soft Starters can be used?Where does the Soft Starters can be used?
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Emerson Confidential
Wood & LumberProblems:
High Inertia Load
High Torque or Current Starts
Solution: Torque Ramp For Linear Acceleration
Shaft Power Monitoring
Where does the Soft Starters can be used?Where does the Soft Starters can be used?Where does the Soft Starters can be used?
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Emerson Confidential
Refrigeration/CompressorsProblems:
Mechanical shock for compressor, motor, and transmission
Small fuses
Wrong direction rotation
Solution: Linear torque
ramp
Phase sequence alarm
Shaft power monitoring
Where does the Soft Starters can be used?Where does the Soft Starters can be used?Where does the Soft Starters can be used?
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Emerson Confidential
Problems: High Inertia Load
Controlled Stop
Positioning for Loading or Unloading of Material
Solution: Torque Ramp For Linear
Acceleration
Dynamic DC Braking without Contactors
Slow Speed Control for Positioning
Shaft Power Monitoring
CENTRIFUGE
Where does the Soft Starters can be used?Where does the Soft Starters can be used?Where does the Soft Starters can be used?
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Emerson Confidential
Problems: High Inertia Load
Fast Stop for Safety and Production
Worn Out or Broken Tools
Solution: Linear Acceleration
Controlled Plug Braking
Shaft Power Monitoring
PLANERS
Where does the Soft Starters can be used?Where does the Soft Starters can be used?Where does the Soft Starters can be used?
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Problems: Different Materials
Control Material Viscosity
Broken or Damaged Blades
Two Speed Motors
Solution: Torque Ramp gives
Linear Acceleration
Shaft Power Monitoring
MIXERS
Where does the Soft Starters can be used?Where does the Soft Starters can be used?Where does the Soft Starters can be used?
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Emerson Confidential
Advantages Of Using Soft StartersAdvantages Of Using Soft StartersAdvantages Of Using Soft Startersz Decreases mechanical costs associated with impact forces on
start-up Allows longer belt/gear life and lowers maintenance costs
by minimizing the forces transmitted through gears, bearings, belts and couplings, reducing replacement frequency
z Minimizes electrical costs associated with motor voltage spikes Reduces motor re-winding frequency due to lower
electrical stress Can enable large electrical utility savings by reducing peak
demandsz Increases Asset Availability
Enables improved systems performance by reducing unplanned shutdowns and increasing productivity
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Simple Reasons For Using Soft StartersSimple Reasons For Using Soft StartersSimple Reasons For Using Soft StartersTo Eliminate
z Nuisance tripping due to high inrush peak starting current.z Excessive contact wear and periodic replacements due to arcing.z Costly maintenance time working on Electro-Mechanical starters.z Stress on the motor insulation due to voltage spike caused by
contactor switching.z Excessive starter/motor replacement due to frequent starting.z Diesel generator voltage and frequency dip.z Excessive bearing wear and damage to mechanical drive train due to
high starting torque.z Spillage or damage to product caused by high starting torque.z Shaft damage associated with wind milling.z Broken belts due to unprotected across line starting.
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Starting MethodsStarting MethodsStarting Methods
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Hazardous Areas (NEMA):Hazardous Areas (NEMA):Hazardous Areas (NEMA):z IEEE 841 z API 547z API 541
z PIPsz Internal company specifications
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The Three Main Oil & Gas Specs:The Three Main Oil & Gas Specs:The Three Main Oil & Gas Specs:IEEE 841, API 547, API 541
z All three specifications developed for use in the Petro Chemical Industry.
z There is some overlap in the specifications. There also are some voids between the three
specifications!z Generally, one specification is more appropriate
than others in any given situation.
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New API547New API547New API547API 541z Critical
applicationz High Risk /
Exposure z Highly
Engineered On-site
Support Upfront
requirements
z Long Manufacturing time
IEEE 841/ Severe Duty
z Redundant and Non-critical application
z Limited specz Low Riskz Speed of delivery
API 547z Critical applicationz Moderately
Engineered / Spec 3 page requirements
z Medium Riskz Speed of deliveryz Cost
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Application GuidelinesApplication GuidelinesApplication GuidelinesApplication IEEE 841 API 547 API 541Coupled Loads Y Y YBelted Loads Y N NAxial Thrust Loads Y N YCentrifugal Compressors Y Y YReciprocating Compressors U U YCentrifugal Pumps Y Y YVertical Turbine Pumps Y N YFans & Blowers Y Y YInduction Generators N N YDivision 2 (Zone 2) U U YAdjustable Speed Drives (ASD) U U Y
U = Unusual condition, notify motor manufacturer
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Questions?Questions?
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Variable Speed DrivesVariable Speed DrivesVariable Speed Drives
V
A
R
I
D
Y
N
E
T
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Presentation ContentPresentation ContentPresentation Contentz What is VFD
z Terminology
z Motor Speed Basics
z VFD Operation Modes
z VFDs as parts of larger systems
z Major VFD Subsystems/Parts
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What is a VFD / AFD / VSD /ACD ?What is a VFD / AFD / VSD /ACD ?What is a VFD / AFD / VSD /ACD ?
z VFD Variable Frequency Drive
z AFD Adjustable Frequency Drive
z VSD Variable Speed Drive
z ACD - Alternate Current Drive
z Inverter ( ~ )
All of the above terms refer to electronic equipment
that primarily control the speed of an induction motor by
frequency and voltage control
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Motor Speed Motor Speed Motor Speed
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V/F RatioV/F RatioV/F Ratio
V/F ratio produced by a drive controlling a 460V, 60Hz motor
To run the motor at full speed, the drive outputs 460VAC @ 60Hz.
If the motor is to run at 50% speed, the output will be 230VAC @30Hz.
The drive is capable of running the motor above its rated speed(>60Hz). However, the output voltage cannot exceed the input line voltage.
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Speed - Torque RelationshipSpeed Speed -- Torque RelationshipTorque Relationship
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Constant Torque OperationConstant Torque OperationConstant Torque Operation
1.a) Constant Torque, CT1.a) Constant Torque, CT
Constant Torque Volts/Hz
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Constant Power OperationConstant Power OperationConstant Power Operation
1. b) Constant Power (CP)1. b) Constant Power (CP)
Constant Power applications are always run at speeds above base speed, 60Hz and higher.
SoWhat is a Variable-Torque operation/load ?
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z VFDs are generally a part of larger systemz Other components/elements may include
PLCs
Line Fuses
Reactors
EMC Filters etc.
Disconnect Switch
Contactors
Etc..
VFDs as part of larger systemsVFDVFDss as part of larger systemsas part of larger systems
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Rectifier IntermediateCircuit
Inverter M
Ctrl. & Regln. Ckt.
Block Diagram- Typical VFDBlock DiagramBlock Diagram-- Typical VFDTypical VFD
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Major Parts of a VFDMajor Parts of a VFDMajor Parts of a VFD
z AC Line voltage is fed to the rectifier section where it is turned into pulsating
DC by the rectifier diodes
z This pulsating DC is then filtered in the intermediate section into a smooth DC
voltage
z This voltage is then fed to the inverter section where it is chopped up into an
AC voltage of the desired frequency.
z The entire process is controlled and monitored by the control section
Rectifier IntermediateCircuit
Inverter M
Control. Ckt.
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Rectifier ConfigurationsRectifier ConfigurationsRectifier Configurations
Uncontrolled rectifiers
Controlled rectifiers
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Soft-Charge CircuitSoftSoft--Charge CircuitCharge Circuit
z Is part of the Rectifier unit
z Ensures that the inrush current is limited to acceptable levels.
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DC-LinkDCDC--LinkLink
The Intermediate Circuit / DC Link
Two major components to the DC Link section- capacitorsand coils.
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Brake Transistor/Brake CircuitBrake Transistor/Brake CircuitBrake Transistor/Brake Circuit
z Required in applications with quick stops(dynamic braking)
z External brake resistor ordered separately
z Excess voltage, dissipated as heat
z Also used to discharge the capacitors when the drive is shut down.
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Inverter SectionInverter SectionInverter Section
z Even if inverters work in different ways, their basic structure is always the same. The main components are controlled semi-conductors, placed in pairs in three branches.
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Pulse-width Modulation(PWM)PulsePulse--width Modulation(PWM)width Modulation(PWM)
z Most widely used system for generating variable V & F
z Output frequency and voltage controlled by adjusting pulse width of the voltage to the motor
z All drives use PWM: differing pulse shapes to the motor.
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Maximum Cable DistanceMaximum Cable DistanceMaximum Cable Distance
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Fan and Pump Key Features and BenefitsFan and Pump Key Features and BenefitsFan and Pump Key Features and Benefits
Variable (Dynamic) Volts/Hz
- Maximizes Energy Savings
- Automatically Optimizes the drive output to match the requirements of the load
0 10 20 30 40 50 60 70 80 90 100
% Speed
V
o
l
t
a
g
e
Energy savingsEnergy savings
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Fan and Pump Key Features and BenefitsFan and Pump Key Features and BenefitsFan and Pump Key Features and Benefits
Mains Dip Ride through
- The drive can automatically ride through momentary power dips by reducing speed and then returning to set speed when the supply recovers without tripping.
Supply Voltage
Load Speed
Time
Increase uptimeIncrease uptime
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Fan and Pump Key Features and BenefitsFan and Pump Key Features and BenefitsFan and Pump Key Features and Benefits
Skip Frequencies (qty. 3)
- For bypassing of mechanical resonance's - reduces wear on the system
Set Point
Actual Drive Frequency
Skip Frequency 1 Skip Frequency 2
Actual Drive Frequencyjumps past
critical points
Increase machine lifeIncrease machine life
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Fan and Pump Key Features and BenefitsFan and Pump Key Features and BenefitsFan and Pump Key Features and Benefits
Independent PID
- For stand alone process control of flow or pressure or level
- No need for external controller, save $$$
Reference
FeedbackOutput
PID
Drive Frequency
Level Set Point
Level Transducer
Built in process controlBuilt in process control
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Fan and Pump Key Features and BenefitsFan and Pump Key Features and BenefitsFan and Pump Key Features and Benefits
Energy Metering and Operating Cost Indicator
- Power consumed, operating costs per hour, power up time log and maintenance flags are all standard features providing free Asset Management tools.
24
ENERGYkWh
Asset managementAsset management
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VFD Application ExamplesVFD VFD Application ExamplesApplication Examples
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VFD Application ExamplesVFD VFD Application ExamplesApplication Examples
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General Use Open Loop
VFD Application ExamplesVFD VFD Application ExamplesApplication Examples
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VFD Application ExamplesVFD VFD Application ExamplesApplication Examples
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VFD Application ExamplesVFD VFD Application ExamplesApplication Examples
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VFD Application ExamplesVFD VFD Application ExamplesApplication Examples
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Motors + VFD Application ExamplesMotors + VFD Motors + VFD Application ExamplesApplication Examples
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Motors + VFD Application ExamplesMotors + VFD Motors + VFD Application ExamplesApplication Examples
z Melones Field PDVSA
z Motor: 100HP
z Drive: 120KVA
z Application: Progressive
Cavity Pump
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Motors + VFD Application ExamplesMotors + VFD Motors + VFD Application ExamplesApplication Examples
z Bara
Motatn Field
z Beam (Rod)
Pump
z 1 x 125HP
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VFD Application ExamplesVFD VFD Application ExamplesApplication Examples
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Wrap-UpWrapWrap--UpUpz There are no fix rules to choose motors
z Need to take care of environment and application
z VSDs and Soft Starters can be a good option, but
they are not the panacea
z Dont be afraid of ask! Ill be glad to help you!
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Questions?Questions?Questions?
MotorProTrainingElectromagnetism..How magnetic field transmits torque?ElectromagnetismElectromagnetismAlternate CurrentsAlternate CurrentsBasic DC & Electromagnetism TheoryArmatureArmatureFields and InterpolesBrushes and HoldersExploded ViewFinal AssemblyShunt and Series MotorsCompound Wound MotorsPermanent Magnet MotorsDripproof Fully Guarded Self Ventilated (DPFG)Dripproof Fully Guarded Blower Ventilated (DPBV)EnclosuresEnclosuresVariable speed screw compressorsDrax Power Ltd Fuel Blending SystemPicanol textile weaving loomsLeTourneau L1350 loader using 4 x B40 300kW SR traction motorsRotorStator FrameInduction MotorA/C Induction Motor TypesShaded PoleCAP START(Capacitor start, split phase)Three-Phase MotorsThree-Phase MotorsMotor Applications MatrixA/C Induction Motor TypesFramesIEC FramesFrame Power RelationshipTorque Speed CurveOpen Drip Proof (ODP)Total Enclosed Fan Cooled (TEFC)Hazardous Location (XP)Medium Voltage MotorsVertical Motors (Solid and Hollow Shaft)Note: Service Factor = Overload CapabilityInsulation SystemsPowerStandard Horsepower RatingsTorque Power RelationshipTorque Power RelationshipInrushStandard MotorsStarting MethodsACROSS THE LINE CONTACTOR STARTINGStarting MethodsTraditional Methods for Soft Starting Where does the Soft Starters can be used?Where does the Soft Starters can be used?Where does the Soft Starters can be used?Where does the Soft Starters can be used?Where does the Soft Starters can be used?Where does the Soft Starters can be used?Where does the Soft Starters can be used?Where does the Soft Starters can be used?Advantages Of Using Soft StartersSimple Reasons For Using Soft StartersStarting MethodsHazardous Areas (NEMA):The Three Main Oil & Gas Specs:New API547Application GuidelinesVariable Speed DrivesPresentation ContentWhat is a VFD / AFD / VSD /ACD ?Motor Speed V/F RatioSpeed - Torque RelationshipConstant Torque OperationConstant Power OperationVFDs as part of larger systemsBlock Diagram- Typical VFDMajor Parts of a VFDRectifier ConfigurationsSoft-Charge CircuitDC-LinkBrake Transistor/Brake CircuitInverter SectionPulse-width Modulation(PWM)Maximum Cable DistanceVFD Application ExamplesVFD Application ExamplesVFD Application ExamplesVFD Application ExamplesVFD Application ExamplesVFD Application ExamplesMotors + VFD Application ExamplesMotors + VFD Application ExamplesVFD Application ExamplesWrap-Up