AC Motors Fundamentals

ABB Certification Course LV Variable Speed Drives

Level:1

INABB/ATDP-L1/AC-MOTOR 1 August 2001

Motors - General
Terminal Box End shield

Shaft Stator
INABB/ATDP-L1/AC-MOTOR 2

Rotor

Base

AC-motor
AC-motor Stator and Rotor Squirrel-cage Stator coupling Star and Delta

Simplified 1-phase equivalent circuit R1

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Phasor diagram (simplified)

U1 I1 I1 = stator current I2 = rotor current Im = excit. current = flux =U1/f1

L1

L2

U1 f1

I1

Im

Lm

I2

I2

R2/s
Im

Equivalent circuit
R1 = stator resistance R`2 = rotor resistance L1 = stator stray inductance L`2 = rotor stray inductance I1 R1
j 1 1L
'

j 2 1L
'

Lm = stator inductance I1 = phase current I2 Im = magnetizing current I`2 = rotor current U1 = phase voltage Ui = air gap voltage 1 = (2f1) angular speed of supply voltage 2 = (2pn) angular speed of rotor voltage
1 2

Im
U1, f1 Ui
j m 1L
'

'

INABB/ATDP-L1/AC-MOTOR 4

Star-delta-coupling

7 I/IN star delta 6 5 T-delta 4 3 M

INABB/ATDP-L1/AC-MOTOR 5

T/TN I-delta 2,5 2,0 1,5 I-star T-star T-load 0 0,25 0,5 0 0,75 n/nS 1,0 1,0 0,5

2 1 0

Torque and slip

TK motor torque TM

T Tacc = acceleration torque TA Tacc = TM - TG TN counter torque TG (load)

S = slip

n n s= n
s s
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nN ns

Torque and current of AC-motor

ns =

f p

n min
s

= 1

60 * f / Hz p

current I

TA = breakaway torque TK = peak torque TN = nominal torque ns = synchronous speed p = pole pairs Example of 4-pole motor, ns = 1500 1/min:
INABB/ATDP-L1/AC-MOTOR 7

T I

TK

Torque T TA
eddy-current motor braking -1 0
TN

n/ns

-1 = reverse 1500 1/min 0 = stop 0 1/min 1 = forward 1500 1/min 2 = forward 3000 1/min

generator

Power

The mechanical power P2 depends on torque T and rotation speed n:

P2 = 2 n T
P2 n T 1 = kW 9550 1 / min Nm

T 4. quadrant n < 0 reverse T>0 P2<0, generating 3. quadrant n < 0 reverse T<0 1. quadrant n > 0 forward T>0 P2 > 0,motoring 2. quadrant n > 0 forward T<0 n

P2 > 0,motoring P2<0 generating

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Efficiency and losses

P1 electrical power Pcu1 copper losses in stator Efficiency of AC-motor:
loss =P =P
2 1

stator

PFe

iron losses

Padd additional losses P air gap power Pcu2 copper losses in rotor rotor

INABB/ATDP-L1/AC-MOTOR 9

Pfri

friction losses

P2 mechanical power

Torque = k * flux * rotor current

Torque is proportional to the triangular area 0AB With no load: Phasor diagram for torque = 0 two different load rotor current = 0 stator current = exciting current cos = ca. 0 U1
U1

U1

0
= k1*I

I1

I1b T
I2

I2b

T=0 I =I 1
I
U1 / f1

B
INABB/ATDP-L1/AC-MOTOR 10

I2 = 0

1 I 1a I

Tb Ta

I2a
U1 / f1

U 1 / f1

T = k2**I2 = ca. k2**I1*cos

Speed control of AC-motor

Speed can be affected by: 1. Changing the number of pole pairs p gradual adjust of the speed 2. Changing the slip s a) Additional resistance in rotor with slip-ring motor b) Changing the terminal voltage (stator) c) Current transformer cascade (feeding the energy from the rotor back to the net) 3. Changing the stator frequency Converter a) VSI-converter b) CSI-converter

Speed of AC-motor:

n = n (1 s) f = n p (1 s)
s s

standstill: s=1
INABB/ATDP-L1/AC-MOTOR 11

slip at nominal speed: sN = 0,5%...6%

Possibilities to adjust the speed

by changing the number of poles, slip of frequency

number of poles
P=4 P=2

slip-ring machine

n = p (1 s)
n = speed p = pole pairs

load

s = slip f = frequency

load

n T frequency f2
f1 f3

current i 1
i2

INABB/ATDP-L1/AC-MOTOR 12

i3
load load

n
i1< i2 < i3

n
F1< f2 < f3

Torque depends on the rotor slot type

three different winder slots

T/TN 2,5 2,0 1,5 1,0

INABB/ATDP-L1/AC-MOTOR 13

1.

2.

3.

3 2 1

0,5 0 0 0,5

n/ns

1,0

Thermal endurance

continuous duty
P P

S1

intermittent duty S3, S4, S5

P P

time

time

short time duty S2

INABB/ATDP-L1/AC-MOTOR 14

continuous periodic duty S6

P P

P time

time

Torque and Frequency

ACS 600 Single Drive
3 1.5 N

Tmax
2.5 2 1.5 1 0.5
INABB/ATDP-L1/AC-MOTOR 15

1.0

0.5 0 0.25 0.5 0.75 1

0.9

1.25

1.5

1.75

F/f

Motor Loadability with ACS600

Standard aluminium and Cast iron Motors (50 Hz) Isotherm Guidelines
T/Tn, % 120 110 100 90 80 70 60
INABB/ATDP-L1/AC-MOTOR 16

Separate cooling

Temperature rise Class F Note lubrication and voltage levels !!

Temperature rise Class B

50 40 20 40 Frequency (Hz) 60 80 100

Loading capacity of the Motor

Loadability curve can be divided into three ranges :

Low speed range (n<<nr) : In this decreasing cooling capacity of the motor and non sinusoidal voltage cause the fall in the loading capacity.

Standard aluminium and Cast iron Motors (50 Hz) Isotherm Guidelines T/Tn, % 120 110 100 90 80 70 60 50 40

Separate cooling

Temperature rise Class F Note lubrication and voltage levels !!

Field weakening point (n= r) : At this point rated flux is induced and loading capacity is 0.9 1.0. Constant output power range (n>>nr) : It is possible to achieve the rated power of the motor. The decreasing torque value causes the heaviest fall in the loading capacity.

Temperature rise Class B

20

40

60

80

100

Frequency (Hz)

INABB/ATDP-L1/AC-MOTOR 17

Selection rules for VSD applications/ Insulation

dU/dt filter =

Series reactor. dU/dt decrease the changing rate of the phase and main voltages and thus reduce voltage stresses in the windings. dU/dt filter also decreases so called common mode currents and bearing currents Design target; dU/dt- rate of main voltages smaller than 1 kV/us at motor terminals. See manual ABB Industry Oy,ACS 600 dU/dt filter selection guide. (Contd)

INABB/ATDP-L1/AC-MOTOR 18

Selection rules for VSD applications/ Insulation

Common mode and light common mode filters =

Common mode filters are made of toroidal cores installed around motor cables. These filters reduce so called common mode currents in VSD applications and thus degrease the risk of bearing currents. Common mode filters do not significantly affect on the phase or main voltages on the motor terminals Common Mode Filters (CMF)= 3 toroidal cores per each 3 - phase motor cable Light Common Mode Filter (LCMF) = 1 toroidal core per each 3 -phase motor cable For product codes and ordering information, see price list of variable speed drives. For installation instructions see ACW 6xx Drives Hardware Manual Chapter 5

INABB/ATDP-L1/AC-MOTOR 19

Selection rules for VSD applications / Insulation

IGBT converters and random wound low voltage motors (non - Ex)
< 100 kW
UN < 500 V Standard motor

> 100 kW or > ICE 315 > 350 kW

Standard motor +Insulated N-bearing Standard motor + dU/dt filter or Reinforced insulation + Insulated N-bearing Standard motor + Insulated N- bearing + Common mode filter Standard motor + Insulated N- bearing + dU/dt filter + Light Common mode filter of Reinforced + insulated N-bearing + Common mode filter Reinforced + Insulated N- bearing + dU/dt filter + Light Common mode filter

UN < 600 V

Standard motor + dU/dt filter or Reinforced insulation

INABB/ATDP-L1/AC-MOTOR 20

UN < 600 V Reinforced Reinforced insulation insulation insulation + dU/dt -filter + dU/dt -filter Back = standard motor, Blue = special motor is needed, Green = options/ modifications are needed

Selection rules for VSD applications / Insulation

IGBT converters and random wound low voltage motors Ex-motors (EEx d, EEx de, Eex e1), EEx nA, Eex nA, Ex N)
Frames UN < 500 V UN < 600 V < 250 Standard Ex-motor Standard Ex- motor + dU/dt filter or Reinforced insulation > ICE 280 StandardEx motor +Insulated N-bearing Standard Ex - motor + dU/dt filter + Insulated N- bearing or Reinforced insulated N-bearing Reinforced insulation + dU/dt filter > ICE 355 Standard motor + Insulated N- bearing + Common mode filter Standard Ex -motor + insulated N-bearing + dU/dt filter + Light Common mode filter or Reinforced + Insulated N-bearing + Common mode filter Reinforced insulation + Insulated N-bearing + dU/dt filter + Light Common mode filter

INABB/ATDP-L1/AC-MOTOR 21

UN < 690 V

Reinforced insulation +dU/dt filter

Back = standard motor, Blue = special motor is needed, Green = options/ modifications are needed Note 1) ABB does not recommend EEx e-motors for VSD - application

Squirrel cage motor & Converter drive

Check

INABB/ATDP-L1/AC-MOTOR 22

Always Loadability Insulation Earthing (Grounding) Cabling Bearing Currents EMC At high speeds Bearing Construction Lubrication Fan noise Balancing Critical Speeds Shaft Seals Max. Torque At low speeds Lubrication Cooling Electromagnetic Noise

IEC Frame Size 63 -100 112 -200 225 - 280 315, 2- pole 315, others 355, 400 2 -pole 355, 400, others

Rotation Speed (r/min) 6000 4500 3600 > (4 - pole: metal fan) 3600 3000 (metal fan) 3600 2500

Increase of the sound pressure level when the speed is changed from n1 to n2

DLsp = 60. log

n2 n1

dB(A)

Faridabad Works (Manufacturing range)

INABB/ATDP-L1/AC-MOTOR 23

Type Output Voltage Frequency Duty Ambient Altitude Insulation

Three-phase squirrel-cage induction motors 0.18 315 kW; 0.25 425 hp 415 V; 220 660 V 50 Hz; 25 .. 60 Hz S1 .. S8 acc. to IS: 12824 45oC; 20 70oC up to 1 000 m Class F/Class H (VPI on request)

Motors - Manufacturing range

Dimensions Enclosure

Cooling

INABB/ATDP-L1/AC-MOTOR 24

Degree of protection Mounting

Housing

Foot-mounted according to IS:1231 Flange-mounted according to IS:2223 Totally-enclosed fan-cooled (TEFC) Totally-enclosed surface-cooled (TESC) Screen protected drip proof(SPDP) IC 01 41 (TEFC) IC 00 41 (TESC) IC 01 (SPDP) IP 23 for SPDP IP 55/IP 56 for TEFC Foot-mounted motors B3, B6, B7, V5, and V6. B8 on request Flange-mounted motors B5, V1, V3, B14, V18, V19, B34 and B35 Cast iron; frames 71 ... 315 Welded steel; frame 355

Motors - Product range

INABB/ATDP-L1/AC-MOTOR 25

Standard three-phase TEFC motors, IS:325 Standard three-phase SPDP motors, IS:325 M2000 motors, IS:325 Agricultural motors, IS:7538 Ring frame motors, IS:2972 Part III Auxiliary motors for a.c. electric locomotives Auxiliary motors for three-phase electric locomotives Non-sparking motors type n, IS:9628 Increased safety motors type e, IS:6381 Roller table motors Crane duty motors Brake motors (externally mounted) Induction generators Wind mill generators Motors for frequency converter drive Custom built motors

Motors - Applications
Duty
S1 S2 S3 S4 S5 S6 S7
INABB/ATDP-L1/AC-MOTOR 26

Application
Pumps,Blowers,Fans,Compressors,etc Operation of gates of dams,sirens, etc Valve actuators, wire drawing machine Hoists, Cranes, Lifts Hoists, Cranes, Rolling mills Conveyors, Machine tools Machine tools Special application - run at different speeds

S8

Standards

HX Motors are designed so that the performance complies with lS:325. HX Motors are totally-enclosed three-phase squirrel- cage type complying with relevant Indian Standards List of Indian standard applicable to low-voltage induction motors are as given below
Title Three- phase induction motors (fifth revision) Code of practice for installation and maintenance of conduction motors (second revision) Dimensions of three-phase foot-mounted induction motors (third revision) Dimensions of flange mounted a.c. Induction motors first revision)

IS No. IS 325 :1996 IS 900 : 1992

INABB/ATDP-L1/AC-MOTOR 27

IS 2231 : 1974 IS 2223 : 1983

Standards
IS 2253 : 1974 Dimensions for types of construction and mounting arrangement of rotating electrical machines (first version) Dimensions of vertical shaft motors for pumps (second revision) Dimensions of slide rails for electric motors Guide for testing three-phase induction motors Degrees of protection provided by enclosure for rotating electrical machinery (first revision) Rotating electrical machines (first revision)

IS 2254 : 1985 IS 2968 : 1968 IS 4029 : 1967 IS 4091 : 1985

INABB/ATDP-L1/AC-MOTOR 28

IS 4722 : 1992

Standards
IS 4728 : 1975 IS 4889 : 1968 IS 6362 : 1971 IS 7538 : 1975 IS 7816 : 1975 IS 8151 : 1976
INABB/ATDP-L1/AC-MOTOR 29

Terminals marking and direction of rotation for rotating electrical machinery (first revision) Method of determination of efficiency of rotating electrical machines Designation of methods of cooling of rotating electrical machines Three-phase squirrel cage induction motors for centrifugal pumps for agricultural applications Guide for testing insulation resistance of rotating machines Single-speed three-phase induction motors for dividing lifts Dimensions and output ratings for foot-mounted electrical machines with frame numbers 355 to 1000

IS 8223 : 1976

Standards
IS 8789 : 1978 IS 12065 : 1987 IS 12066 : 1987 IS 12075 : 1986 Values of performance characteristics for threephase induction motors Permissible limits of noise level for rotating electrical machines Three-phase induction motors for machines tools Mechanical vibration of rotating electrical machines with shaft heights 56mm and highermeasurement, evaluation and limits of vibration severity (superseding IS 4729:1968) Energy efficient three-phase squirrel cage induction motors Temperature rise measurement of rotating electrical machines

IS 12615 : 1989 IS 12802 : 1989

INABB/ATDP-L1/AC-MOTOR 30

Standards
IS 12824 : 1989 IS 13107 : 1991 Type of duty and classes of rating assigned to rotating electrical machines Guide for measurement of winding resistance of an a.c machines during operation at alternating voltage Guide on effects of unbalanced voltages on the performance of three - phase cage induction motors Guide for selection and applications of three phase a.c induction motors for different types of driven equipment

IS 13529 : 1992

IS 13555 : 1993

INABB/ATDP-L1/AC-MOTOR 31

Bearing Currents in Converter Drive

Converter voltage differs from a symmetrical sine wave system I,e. The sum of phase voltage is not zero: UA + UB + UC)/3 # 0 High frequency common mode voltage and common mode current Unsymmetrical supply system! Rapid voltage changes (dU/dt= high) with equipment stray capacitances make new high frequency current paths available Two main categories for ICE 315 and higher motor sizes Circulation current due to high frequency axial shaft voltage Shaft grounding current due to high frequency motor frame to ground voltage Category I - Circulating current Higher power motors Not a problem with low power motors (roller table motors etc.) High PE-current High bearing temperature With IGBT drives damage periods vary from few weeks to few months With GTO drives the damage periods are longer due to lower dU/dt-values and switching frequencies

INABB/ATDP-L1/AC-MOTOR 32

Bearing Currents in Converter Drive

Remedies : Common mode choke dU/dt- filters One bearing insulation Category II - Shaft grounding current Unsymmetric / wrong cabling arrangements Poor stator grounding Good grounding of the shaft through the gear/ driven machine Depends on various random factors : Motor / gear installation Potential equalising conditions of the motor frame Grounding conditions of the driven machine

INABB/ATDP-L1/AC-MOTOR 33

Shaft grounding currents may flow through the bearing/ bearings Damage periods vary depending on the actual drive and installation setup

Bearing Currents in Converter Drive

Category II - Shaft grounding current Remedies : Correct cabling arrangements Common mode choke dU/dt - filters Low impedance potential equalising of the motor frame Insulated coupling No reported bearing failures due to circulating - or shaft grounding current in low power or < 315 frame size motors

INABB/ATDP-L1/AC-MOTOR 34

In low power / small frame size motors the PE-current amplitude is low due to higher common mode impedance of the motor.

The induced shaft voltage is not high enough to cause breakdown in the bearings The probability for shaft grounding current is even lower than in large motor sizes

Bearing Currents in Converter Drive

After numerous field and lab measurements :

The great majority of the existing bearing current damages in converter driven 315 and higher motor size is caused by the circulating current The existence of shaft grounding current depends on various random factors :

Motor / gear installation Potential equalising conditions of the motor frame Grounding conditions of the driven machine

INABB/ATDP-L1/AC-MOTOR 35

Very high shaft grounding currents are related to miscarried cabling / grounding arrangements

Bearing currents are not black magic : Physical background is simple and now well known Currents can be measured from a running drive Solution for problem elimination exist ABB is developing different solutions for future installations

Bearing Currents in Converter Drive

INVERTER

2
MOTOR CABLE

MOTOR

GEAR

LOAD

4 7 3 5 6

1
INABB/ATDP-L1/AC-MOTOR 36

Common mode voltage pulse - DC High frequency common mode current PE-current

+ DC

2 1 3

4 6

High frequency shaft voltage

High frequency circulating current Shaft grounding current

High frequency frame voltage

Motor cabling Attenuating of interference

Concentric shield, (PE)
PE

Concentric shield, (PE)

PE

Asymmetric, shielded cables LF and interference possible if installed in a wrong way Bearing currents possible if installed in a wrong way Proper way of installation Shield connected at both ends

Symmetric, shielded cables Controlled high frequency current flow due to flow impedance return path (draining transformer effect) Decreased low frequency interference due to symmetrically

INABB/ATDP-L1/AC-MOTOR 37

Asymmetric, non-shielded or single core cable cause : Uncontrolled high frequency current flow Low frequency interference High frequency interference Bearing currents Decreased drive availability

Motor cabling Attenuating of interference

Concentric shield, (PE)
PE

Concentric shield, (PE)

PE

PE-Conductor connected only at the inverter end

Always check local safety code

INABB/ATDP-L1/AC-MOTOR 38

If shield conductivity is not sufficient an additional separate PE conductor is needed

Minimized interference to other equipment Increased drive availability Minimized shaft grounding current possibility

Not recommended for AC drive motor cables

Temperature limits for insulation materials

highest ambient temperature over temperature limit (resistance measurement) H thermal reserve d 180oC ly Use F n o m Co m 155oC 15 B 10 E 130oC

Hotspot

A 105oC

120oC

10 5 105 125

5 60
INABB/ATDP-L1/AC-MOTOR 39

75

80

40 0oC

40

40

40

40

Motors - Manufacturing Stages

Machined Housing Stack pressing Coil mounting Impregnation Rotor
INABB/ATDP-L1/AC-MOTOR 40

Dynamic balancing Shaft insertion Die-cast rotor

A s s e m b l y

T e s t i n g

Painting & Packing

Motors - Internal Components

INABB/ATDP-L1/AC-MOTOR 41