Motor Basics

Technical Overview
 Topics

• Motor Basics
• Motor Construction
• Application of Variable Speed Motors

Motor Basics.PPT 02/08/01

 Motor Basics

• Magnetism and Induction

• Motor Speed Relationship
• Motor Performance
• Efficiency
• Explosion Proof

Motor Basics.PPT 02/08/01

 Magnetism and Induction

– Motor Converts Electrical Energy Into Mechanical

Energy
– AC Alternating Current Reverses Poles of Electro-
magnetic Coil 120 Times Per Sec (60hz)
– Coils Inserted in the Stator of the Motor Create
Rotating Magnetic Field
– Magnetic Field Passing Through the Conductors of the
Rotor Induces Current to Flow
– Induced Current Produces Magnetic Field Around
Rotor Conductors Which Creates Magnet
– Rotor and Shaft Follow the Rotating Magnetic Field of
the Stator

Motor Basics.PPT 02/08/01

 Magnetism and Induction

Time 2 Time 4 Time 6

A1 A1 A1
S N

B2S C2 C2 B2N C2
N B2 S

S N N S
C1 B1 C1 B1 C1 B1
N S

A2 A2 A2
Time 1 Time 3 Time 5 Time 7
A1 A1 A1 A1
N S N

B2 C2 B2S C2 B2N C2 B2 C2
N S N

S N S S
C1 B1 C1
N
B1 C1 B1 C1 B1
S
S N

A2 A2 A2 A2

B Time

0° 60° 120° 180° 240° 300° 360°

 Motor Speed Relationship
– Synchronous Speed Is the Speed of the Rotating Magnetic Field Set
up by the Stator Winding
– Synchronous Speed (RPM) = (120 X Frequency) / Number of
Poles
– As Load Torque Is Required From the Motor, Rotor Speed Will
Decrease Relative to the Rotating Field. This Is Called “Slip”
– “Slip” Induces Current to Flow in the Rotor Which Interacts With
Rotating Field and Produces Torque Which Is Transmitted to the
Load
– Synchronous Motor With Reluctance or Permanent Magnet Rotor
Have No Slip and Provide Exact Speed up to Full Load Rating

Motor Basics.PPT 02/08/01

 Motor Performance

Speed - Torque Curve

P BREAKDOWN TORQUE
E STARTING TORQUE
R
300
FULL VOLTAGE
Torque - % full load

C
250
E PULL-UP TORQUE
N
200
T
FULL LOAD
150
TORQUE
T
O 100
R
Q 50
U
E 0
0 1800
1740 rpm
Speed - RPM

Motor Basics.PPT 02/08/01

 Motor Performance

– Standard NEMA Designs of Various Torque

Characteristics to Meet Different Application Loads

NEMA Starting Starting Breakdown Full Load Typical sine wave

Design Torque Current Torque Slip Applications
A Normal High High Low Mach. Tools, Fans
B Normal Normal Normal Normal General Industrial
Loaded Compressor,
C High Normal Normal Normal
Loaded Conveyor
D Very High Low High Punch Press or Hoists

Motor Basics.PPT 02/08/01

 Motor Performance

- The Service Factor on a Motor Nameplate

Indicates How Much Above the Nameplate
Rating a Motor Can Be Continuously
Loaded.
- Example: 40hp 1.15sf Is Good for 46hp
Continuously
- 1329R Motors Are Rated 1.0sf on Inverter,
1.15sf on Sine Wave

Motor Basics.PPT 02/08/01

 Efficiency

• All Allen-Bradley 1329R Motors Meet EPACT

Efficiency Requirements
• Two Efficiency Levels
– Energy Efficient
– Premium Efficient

Motor Basics.PPT 02/08/01

 Efficiency

Losses

Input
Power
(Watts)
Load
(Output power
A-C Motor 1 HP = 746 Watts)
(power lost during
conversion)

Motor Basics.PPT 02/08/01

 Efficiency

• Induction Motor Energy Losses

2
– Primary I R (Winding)
– Secondary I2R (Rotor)
– Core Losses (Iron)
– Friction & Windage (Fan)
– Stray Load Losses

Motor Basics.PPT 02/08/01

 Efficiency
• Additional Active Material
– Winding
– Rotor
– Stator Core
• Improve Quality of Steel
• Thinner Laminations
• Fan Design (Low Loss)
• Improved Manufacturing Processes

Motor Basics.PPT 02/08/01

 Efficiency

150 HP,1800 RPM, 445 T Frame Rotors

Standard Premium

Motor Basics.PPT 02/08/01

 Efficiency

• Economical • Operational

– Energy Savings – Lower Noise

– Reduced Load – Cooler running
– Utility Rebates – Longer Life

Motor Basics.PPT 02/08/01

 Efficiency
- All 1329R Variable Torque Motors are Energy
Efficient
- All 1329R Constant Torque 180 Frame and
Larger Motors are Premium Efficient
- Nominal Efficiencies Shown in Product
Literature

Motor Basics.PPT 02/08/01

 Explosion Proof

Class I Potentially explosive flammable gases or vapors in the air

Class II Combustible dust in the air
Class III Ignitable fibers or flying (dust) in the air

Group A Acetylene
Group B Hydrogen, gases or vapors of manufactured origin
Group C Ethyl-ether vapors, ethylene or cyclopropane
Gasoline, hexane, naphtha, benzene, butane, propane, alcohol,
Group D
acetone, benzyl, lacquer, solvent vapors, or natural gas (methane)
Conductive dust and metal dust: aluminum, magnesium - their
Group E commercial alloys, etc.
Group F Carbon black, coal, or coke dust
Group G Flour, starch, grain dusts

Div 1 Location where hazardous material exists (always or periodically)

during operating conditions
Location where hazardous material exists only in the case of fault
Div 2
situation (leaky valve, burst pipe, faulty equipment)
 Explosion Proof

T Code Max. Surface Temp. is Min. UL Requirement for:

T1 450º C (842º F)
T2 300º C (572º F)
T2A 280º C (536º F) Class I, Gr D w/caution label
T2B 260º C (500º F)
T2C 230º C (446º F)
T2D 215º C (419º F) Class I, Gr D w/Thermals
T3 200º C (392º F) Class II, Groups E & F
T3A 180º C (356º F)
T3B 165º C (329º F) Class II, Group G
T3C 160º C (320º F) Class I, Group C
 Explosion Proof

Division 1 - Explosion-Proof
Dust Ignition-Proof
Class I - (Gases) Group A, B, C & D
- Maximum Explosion Pressure
- Maximum Safe Clearance of Fits
- Minimum Ignition Temperature

Class II - (Dusts) Groups E, F & G

- Tightness of joints
- Shaft Opening Clearance
- Blanketing Effects of Dust
- Electrical Conductivity of
Dust
- Ignition Temperature of
Dust
 Explosion Proof

Division 2

Class I - (Gases) Group A, B, C & D

Consider - Minimum Ignition Temperature
- Internal
- External

Class II - (Dusts) Groups E, F & G

Consider - Minimum Ignition Temperature
- Conductivity of Dust
 Explosion Proof

• Maximum Explosive Pressure

– Heavier Frame
– Longer Rabbet Fits 3/4” vs 1/4”
• Maximum Safe Clearance (flame path)
– Longer Rabbet Fits
– Closer Machine Tolerance
– Inner Cap & Shaft Clearance/Seals
– Potted Lead Outlet
• Minimum Ignition Temperature
– Low Rise Design
– Special Insulation or Thermostats
 Motor Construction
• Enclosures
• Frames, NEMA Definitions
• Motor Construction and Components
• Mounting Methods
• Insulation System
• Nameplate Nomenclature

Motor Basics.PPT 02/08/01

 Enclosures

Open
– Protected - PROT
– Drip-proof Force Ventilated - DPFV
– Weather Protected - Type I & II

Totally Enclosed
– Non-ventilated - TENV
– Fan Cooled - TEFC
– Blower Cooled - TEBC
– Air Over - TEAO
– Dual Cooled - TEDC-A/A (Air to Air) or -A/W (Air
to Water)
– Explosion Proof - TEFC-XP

Motor Basics.PPT 02/08/01

 Frame Size

• Refers to a Set of Physical Motor Dimensions As Established by NEMA

– 48 and 56 Frame Motors Are Fractional Frame Sizes
– 180T Through 449T Are Considered Integral Frame Sizes
– 5000 Frame and Above Are Considered Large Frames (Non-
NEMA)

Motor Basics.PPT 02/08/01

 Frame Size

48 - 145T FRAMES
FC56CYZ (example)

– Two Numbers - D Dimension Is the Frame Size in 1/16 ths of an Inch - I.E. 56 / 16 =
D Dimension of 3.5” - Preceding Letter(s) May Indicate Length
– Three Numbers - D Dimension Is First Two Digits in 1/4 ths of an Inch - I.E. 14 / 4 =
D Dimension of 3.5” - Third Digit Indicates Length
– Preceding Letters Are for Use by Individual Manufacturer
 Frame Size

182T - 449T FRAMES

213TCYZ (examples)

– Three Numbers - D Dimension Is First Two Digits in 1/4 of an Inch - I.E. 21 / 4

= D Dimension of 5.25” - Third Digit Indicates Longer Distance Between
Mounting Bolt Holes
 Frame Size

Frame Suffix Nomenclature (449XX)
C Face Mounting on Drive End
D Flange Mounting on Drive End
P Vertical Pump Mounting Flange on Drive End
HP Vertical Pump Mounting Flange, Normal Thrust
LP Vertical Pump Mounting Flange, Medium Thrust
S Standard Short Shaft for Direct Coupled Only
T Standard Shaft for NEMA “T” Frame
U U-frame Motor (Automotive Industry)
Y Special Mounting Dimensions
Z Special Shaft Dimensions

Motor Basics.PPT 02/08/01

 NEMA Frame Standards

AUTOMOTIVE DUTY U-FRAMES

182- 449U FRAMES
• Each Frame Size Has Specific HP Assigned by Speed
• Meets Ford EM-1, Chrysler NPEM-100, GM 7EQ and 7EHQ
Specifications
• 7EQ Is GM Standard Efficient Spec
• 7EHQ Is GM Energy Efficient Spec
• One Frame Size Larger Than Standard T-Frame at Same
Horsepower
• Most Modifications Available
 Motor Construction

Motor Basics.PPT 02/08/01

 Motor Construction

Stator & Rotor Epoxy

Coating
Cast Iron
Construction

PLS® Bearing
Anti-static Lubrication System
Polypropylene
Corrosion
Resistant Fan

V-Ring Slinger

Stainless Steel
Cast Iron
T-Drains
Conduit Box
Neoprene Lead
Separator

Motor Basics.PPT 02/08/01

 Motor Construction

Bearing Designs
• Thrust and Radial Load
Considered
• Anti-friction - Grease
Lubricated
– Open / Shielded
– Ball / Roller
• Sleeve Bearing - Oil
Lubricated
• Thrust Bearing - Grease or
Oil

Motor Basics.PPT 02/08/01

 Motor Construction

Shaft Coupling
• Ball Bearing Coupled or Belted
(444T Frame and Smaller)
• Roller Bearings - Belt Duty Only
• ‘TS’ Designation is for Coupled
Duty Only
• Check Motors-CA001A-EN-P for
Details on Bearing Loading
Capabilities

Motor Basics.PPT 02/08/01

 Motor Construction

• Positive Lubrication
System (PLS®)
– Cooler Bearing Temperatures
– Positive Lubrication / Re-
lubrication in Any Mounting
Position
– Minimizes Corrosion
– Restricts Inboard
Contaminants
– Prohibits Over Greasing
During Lubrication / Re-
lubrication

Motor Basics.PPT 02/08/01

 Mounting Methods


Horizontal / Vertical

Foot mounted

Flange mounted
– With Feet
– Without Feet

Motor Basics.PPT 02/08/01

 Mounting Methods

C-Face with Feet

D-Flange with Feet
Vertical P-Base with Drip
Cover

Motor Basics.PPT 02/08/01

 Insulation Systems


Considerations
– Rate of Rise of Voltage
– Voltage Between Phases
– Reflected Voltage
– Installation Issues

Motor Basics.PPT 02/08/01

 Insulation Systems
• Insulation Is Required Anywhere in the Motor Where There Is
a Difference of Electrical Potential Between Two Conductors.
• Insulation System Consists of
– Magnet Wire Insulation
– Resin Insulation
– Slot Insulation
– Coil Head Insulation
– Assembly Techniques
• An Insulation System Is Much More Than the Sum of Its
Components

Motor Basics.PPT 02/08/01

 Insulation Systems

Top Stick

Insulating
Resin
Mid
Stick

Wire

Slot Liner
Motor Slot Insulation

Mid Stick (Phase to Phase)

Top Stick (Phase to Ground)

Slot Liners (Phase to Ground)
Stator Core

Motor Basics.PPT 02/08/01

 Insulation Systems

• Coil Head Insulation

– Phase Paper
– Lead Insulation
– Lacing and Tape
– Resin
– Solvent Borne
– 100% Reactive

Motor Basics.PPT 02/08/01

 Insulation Systems

• Manufacturing Techniques
Include: (A)
– Winding Type
– Hand Inserted / Lap
Wound (A)
– Machine Inserted/
Concentric Wound (B)
– Placement of Insulation (B)
Materials
– Resin Application Process
– Dip & Bake
– Flow
– Vacuum Pressure
Impregnation

Motor Basics.PPT 02/08/01

 Insulation Systems

• An Insulation System Is More Than the Sum of Its

Components
• A-B Motor Insulation Systems Meet and Exceed NEMA MG1
Part 31.40.4.2
• Utilize CIV* Testing at Rated Operating Temperature to
Evaluate Insulation System
• Insulation Rating
Minimum 1600v Peak CIV for 460v Motors, at Rated Operating Temperature *
Minimum 1850v Peak CIV for 575v Motors, at Rated Operating Temperature *

* Rockwell Automation Test Method

Motor Basics.PPT 02/08/01

 Nameplate Nomenclature

BULLETIN 1329R
INVERTER DUTY
MOTOR
MADE IN U.S.A.

ENERGY EFFICIENT XT - EXTRA TOUGH/SEVERE DUTY

FRAME
IDENTIFICATION NO. SIZE
HP VOLTS PHASE DESIGN TYPE
RPM AMPS HZ AMB ºC SF
DRIVE END INSUL
BEARING DUTY CLASS
OPP D.E.
BEARING ENCL CODE

613-6-RR
CONSTANT
TORQUE RANGE
A-B CATALOG NUMBER

Motor Basics.PPT 02/08/01

 Variable Speed Applications

• Torque and Horsepower

• Load and Speed Range
• Cast Iron vs. Laminated Frame

Motor Basics.PPT 02/08/01

 Torque and Horsepower

torque (ft. lb.) x speed

Horsepower =
5250

Torque = horsepower x 5250

speed

Motor Basics.PPT 02/08/01

 Load and Speed Range
• Type of Load
– Constant Torque
– Variable Torque
– Constant Horsepower

Motor Basics.PPT 02/08/01

 Load and Speed Range
• Constant Torque
– Heat Generated Is Same at All
Speeds
– Cooling System Deteriorates at
Reduced Speed Unless Equipped
With Blower or the Motor is TENV
– Following Is a Graph of 4:1 CT
Continuous Duty

Motor Basics.PPT 02/08/01

 Load and Speed Range

Constant Torque 4:1

100
Torque
90

80
Torque
70

60

50

40

30 Acceptable Region
for Continuous Operation)
20

10
0
0 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90

HZ

Motor Basics.PPT 02/08/01

 Load and Speed Range

• Variable Torque
– Typical of Centrifugal Pumps and Fans
– Torque Drops As Square of Speed
Reduction
– Operation at Low Speed Not a Problem Due
to Low Torque Requirement
– Motor Enclosure Dependant Entirely on
Environmental Needs - Not Thermal

Motor Basics.PPT 02/08/01

 Load and Speed Range

• Constant Horsepower Operation

– Torque Tapers Off Above Base Speed
– Constant Power Required at High RPM
– Common Applications Include:
• Winders
• Machine Tools
• Transmission Test Stands / Dynamometers

Motor Basics.PPT 02/08/01

 Load and Speed Range

Constant Torque to Zero Speed / 2:1 Constant Horsepower

Torque Horsepower
100%
Constant Torque Range Constant Horsepower Range
Torque &
Horsepower

0 100% 200%
Percent of Base Speed

Motor Basics.PPT 02/08/01

 General Purpose and High Performance
• 1329L has higher power density for better space
utilization
• Lower rotor inertia allows higher dynamic
responsiveness

Allen-Bradley Allen-Bradley
1329L 1329R

Motor Basics.PPT 02/08/01

 Exercises

• Base speed selection exercise (GP Motor)

- 40hp fan application
• DPFV vs. TEBC
• Enclosure selection

Motor Basics.PPT 02/08/01