Interpreting Motor Nameplate Data: Exercise E410-S02.wpd

Course 410-500 11/01/98
Industrial Motor Maintenance Exercise
Exercise E410-S02.wpd
Interpreting Motor Nameplate Data

Objective
Using the Electric Motor Repair Training Manual #562-MAN, the DAC #410-#419 Motor Fundamentals Training System motor nameplates and the nameplates on motors in your workplace, identify common motor types and operational characteristics.
Performance Standard
Identify all the italicized terms and components with 100% accuracy.
Foundation Competencies
Knowledge of AC motor terminology and construction (Exercise E410-S01).
Required Background Reading
Electric Motor Repair Manual, pgs. 12, 99-101. (DAC, #562MAN)
Tools Required
Pencil and paper.
Components Required
Any of the DAC #410-#419 Motor Devices.
Introductory Discussion
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The National Electric Code (NEC) Article 430 requires all motors to have nameplates with certain information useful in the identification of the type of motor, selection of motors for applications, and the repair and troubleshooting of the motor. It is the first place to look to determine exactly what you have or to verify on what you are working. In this exercise you will have the opportunity to investigate the nameplates of several motors and determine what types of information they provide. Given the many functions throughout industry that motors perform, it is important that you know how to recognize the proper motor when you see one. The best way is to become thoroughly familiar with what information is available on a motors nameplate.
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Performance Steps
Step 1. Identify the basic terms and types of information found on the typical motor nameplate.
Figure 1 DAC #410 Split Phase, CapacitorStart AC Motor Nameplate
Identify the information listed on typical motor nameplates. Manufacturer Phase/Frequency Type or Style Service Factor Frame Size Insulation Class Rated Power (HP) Ambient Temp. Rated Voltage Rated RPM/Speed Full Load Amperage Duty or Time NEMA Design Letter KVA Code Letter Efficiency Power Factor Enclosure Type Connection Diagrams
Figure 2 DAC #412 Three-Phase, Capacitor-Start AC Motor Nameplate
Note that not all nameplates contain all this information and some can even contain additional information. Using the motors in the DAC Motor Fundamentals Training
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System and/or the motors in and around your workplace, identify and record for each the information contained on their nameplates, as each type of entry is discussed in this exercise.
List the motors available on individual sheets of paper or large index cards for this exercise by their Name, ID Number, Usage or Location, so that you know which is which physically. Identify the Manufacturers Names on available motors. List at the top of each page or index card the name of the motors manufacturer. In some cases additional manufacturers information is included such as their address. To obtain the most experience from this exercise it would be best if you are including a variety of different manufacturers. List also any identification numbers or serial numbers that identifies the motors in your facility and/or this exercise. Some nameplates also include a Catalog # or a Part No. which can be used to re-order an exact replacement from the manufacturer. Some nameplates also include a user number which would be an identification number for your company with the manufacturer. Identify the Type of each motor available. List under the Manufacturers Name on each page or index card the type or model letter designator for that motor. This letter designation tells you the specific style of the motor, which you need to know to be able to troubleshoot and repair the motor, such as a Split Phase, Capacitor-Start Motor or a Three Phase Squirrel Cage Rotor Motor. Identify the Frame Size of the motors available. List the Frame Number on each page or index card.
Step 2.
Step 3.
Step 4.
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The National Electrical Manufacturers Association (NEMA) Frame Size Number is a code that can lead you to all the critical dimensional measurements of the motor, such as shaft height, shaft length, shaft diameter, distances between mounting bolts, overall length of the motor, and the diameter of the motor. This is an attempt to help ensure interchangeability of motors between manufacturers. The full load torque of a motor has more impact on the frame size than its horsepower. Note: The industry went through two re-ratings of motors; one in 1952 and the second in 1964. Older motors (before 1952) are called pre-U frames, (after 1952 but before 1964) are U frames, and newer motors (after 1964) are T frames for motors up to 250 HP. There are other letter designations that describe the motor and/or its usage. The data can be found by looking up this indicator in a copy of the National Electrical Code Handbook. Identify the Power Rating of the motors available. List the stated horsepower (HP) rating of each motor on each page or index card. This is the rated mechanical horsepower or full load kilowatt (KW) rating output of the motor. It is the measure of work the motor can do. It is measured at the rated voltage and current and at the proper applied frequency. Motors can be thought of as Torque Generators, a device that produces a twisting or turning force to provide rotation to a load. The measurement describes the weight moved, the distance it is moved and the time it takes to do it in accordance with the formula below:
Step 5.
FxRxN Load Torque (ft.-lbs.)xRPM Motor HP = ----------------- or -----------------------------------5252 5252
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where: F = Force or scale in pounds R = Radius of the motor pulley in Feet N = Speed of the motor in RPM F x R = Load Torque Step 6. Identify the Voltage Rating of the motors available. List the voltage rating or ratings of each motor on each page or index card. The rated voltage on the motor nameplate is usually lower than the voltage source of the electrical system. An assumption is made by the motor manufacturer that there will be a voltage drop of some amount from the systems transformer down to the motor terminations. For example, a 460 volt motor is designed to operate on a 480 volt system; the assumed voltage drop would, therefore, be 20 volts. The following chart shows the most common system 3 Phase Systems and the typical motor rated voltages associated with each phase-to-phase levels: System and Rated Voltages for Induction Motors 3 Phase System Voltage 216 240 480 600 2400 4160 4800 Rated Motor Voltages 208 230 460 575 2300 4000 4600
Volts
Volts
The rated voltage or voltages on the nameplate represent the voltage(s) at which the motor operates most effectively. When other than rated voltages are applied, the performance of the motor will change and the life of the motor may be reduced. Note: Efficiency remains about the same from 100% to 110% of rated voltage; it will drop off if much lower or much higher.
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Motor current varies inversely with the applied voltage. Higher load currents from lower than rated voltages can cause overload protective devices to trip or can overheat the motor resulting in premature failure. The following chart shows the effects of lower and higher than rated voltages at startup and running conditions: Speed, Torque, and Current Changes Caused By Voltage Variations From Rated Values 90% of Voltage 11% Increase 1% Decrease 19% Decrease 10% Decrease 110% of Voltage 7% Decrease 1/2% Increase 21% Increase 10% Increase 120% of Voltage 11% Decrease 1% Increase 44% Increase 20% Increase
Full Load Current Full Load Speed Starting Torque Starting Current
The motor develops less starting torque with lower motor voltage. This results in longer accelerating time to full speed and can cause the motor to stall.
In three phase motors operating near full power, an unbalance in the voltages across phases of only 3.5% can produce a 25% increase in temperature in some windings. This can severely shorten the life of a motor. Identify the Voltage Connection Diagrams of the AC motors available. If provided, copy the voltage connection diagrams for each AC motor on each page or index card. Many three phase motors have two voltages listed on the nameplate, such as 230/460 volts meaning the motor can be connected for either 230 or 460 volt operation. In these instances different numbers of internal phase coils are being
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Step 7.
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utilized or bypassed. This gives the motor more flexibility. A connection diagram is usually found on the nameplate or attached to the housing or conduit box which identifies each voltage, often only marked Hi Volts and Low Volts opposite the side for the Line connections. Note also that these connection points are numbered or color coded to indicate the terminals they represent inside the motor. Step 8. Identify the Full Load Amperage Rating of the motors available. List the full load amperage (FLA) rating or ratings of each motor on each page or index card. The full load amperage rating or ratings listed on the motor nameplate indicates the current the motor draws at nameplate horsepower, frequency, and voltage. If two currents are listed, the higher current is associated with the lower voltage connection and the lower current is associated with the higher voltage connection. The National Electric Code (NEC) requires that the rated full load current be used as a basis for determining the proper sizing of cables, overload protective devices, and other overcurrent protection circuitry. Identify the Frequency Rating of the AC motors available. List the stated frequency (HZ: Hertz) rating of each AC motor on each page or index card. This is the number of cycles per second that an AC motor is designed to utilize. Induction motors are able to operate at +/- 5% of the rated frequency with no deviation from rated voltage. The changes which do occur under these conditions, however, are: Starting Power Load Torque Speed Efficiency Factor Current Freq. High Decreases Increases Decreases Inc. Dec. Freq. Low Increases Decreases No Change Dec. Inc. The most significant result of a decreasing frequency is the load current increase it can cause, and the damage that this
Step 9.
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can do if the motor runs at the lower frequency for a substantial time period. Step 10. Identify the Speed Rating of the motors available. List the speed, in number of rotations or revolutions per minute (RPM), for each motor on each page or index card. This is the number of rotations the motors moveable element and shaft completes in a minutes time if at full load operating conditions. If the driven load, however, is less than the nameplate horsepower rating of the motor, the shaft will turn faster than the full load speed. If the motor is operating unloaded or disconnected from the load, the shaft will turn at very close to what is called synchronous speed. The motor will operate at speeds from synchronous speed down to its rated speed as the load increases from zero to full load. An induction motor cannot exceed its synchronous speed unless the frequency to the motor has changed. The relationship between frequency and speed of a motor is as indicated by the following formula: 120 x Frequency Speed = -------------------------------------Number of Motor Poles NEMA speed standards for T Frame AC motors are: 3600, 1800, 1200, 900, 720, and 600 RPM; for DC motors: 3500, 2500, 1750, 1150, 850, 650, 500, 400 and 300 RPM. Actual speeds measured, even of unloaded motors, will be lower than these due to the friction of their bearings. The difference in the measured speed and the ideal synchronous speed is called slip. Therefore, the above synchronous speeds are rarely found listed on the nameplate. The full load slip of an induction motor is often expressed in a percent, rather than in RPM. It is calculated as shown below: Synchronous Speed - Nameplate Speed % F.L. Slip = ------------------------------------------------------- x 100% Synchronous Speed Note: NEMA design A, B, and C motors commonly have a full load slip of less than 5%. Design D motors have 5% or more
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slip.
Multi-speed motors are mostly designed in either a single winding or two winding configuration, but it is possible to find multiple speed motors. Multi-speed motors are also available in three application types: Constant torque: A constant torque motor delivers the same torque at each of the nameplate speeds. Rated horsepower output will change proportionately with nameplate speeds. Constant horsepower: A constant horsepower motor has the same horsepower rating at each of the nameplate speeds. Torque output, however, will change inversely proportional to the change in nameplate speed. Variable torque: A variable torque motor has a torque output that changes directly with the nameplate speed. The horsepower output at full load also changes, but with the square of the speed change.
Step 11.
Identify the number of Phases the AC motors available use. List the number of phases each AC motor uses on each page or index card. This is the number of phases of AC power the motor is designed to utilize. Identify the Service Factor of the AC motors available. List the Service Factor (SF) multiplier for each motor on each page or index card. This is the multiplier applied to the motors rated horsepower to determine how much the motor can run overloaded continuously without damaging the motors winding insulation. For example, a 1.15 SF multiplied to a 1 HP motor means it can safely run at 1.15 HP without damage at listed ambient temperature or lower. The benefits of a high Service Factor are that the motor will probably have an extended life, it is
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insurance for temporary overloads, and the motor can be used at high altitudes.
Caution:
Whenever a motor is operated above its rated power, the temperature of the motor windings will increase. For every 10 degrees centigrade rise in insulation temperature, the life of the motor is cut in half! It is strongly recommended that motors be operated within the range of their stated ratings and overloaded only for brief periods.
Step 13.
Identify the Ambient Temperature Rating of the motors available. List the Ambient Temperature Rating for each motor on each page or index card. If this is listed, it is the maximum temperature in degrees centigrade of the surrounding air, which will allow operation at rated horsepower without damage. Identify the Insulation Class of the motors available. List the Insulation Class of each motor on each page or index card. The class of insulation used on the motor windings indicates the maximum operating temperature of the coil windings in the motor. This has more impact on the life span of a given motor than any other single construction decision. Approximately 60% of motors brought to repair shops are there due to premature failure due to overheating the electrical insulation of the motors. There are four temperature classes: A, B, F and H: Degrees Centigrade: Class A Class B Class F Class H Ambient Temp. 40 60 5 105 Temp. Rise 40 80 10 130 Hot Spot Hot Spot Allowance Temp. 40 40 105 125 10 15 155 180
Step 14.
Classes A and B insulations are considered hydroscopic,

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which means that if they operate in a moist environment, or if moisture in the air is allowed to condense on the insulation, some of that moisture is absorbed and retained. As a result, the insulation dielectric effect is reduced and the motors life will also be reduced. Classes F and H insulations are considered non-hydroscopic, which means that they tend not to retain the moisture. These classes should be used in humid environments and in situations where condensation can occur during a motors off cycle. Step 15. Identify the Duty Classification of the AC motors available. List the Duty or Time Rating for each AC motor on each page or index card. This is the length of time the motor can run at full load without overheating and/or shortening the life of the motor. It is also referred to as a motors Duty Cycle. The time or duty rating of a motor is determined by operating the motor at full load and measuring the time it takes for the winding to heat up to the temperature rating of the insulation. A motor with a time, or duty rating other than continuous is a smaller motor that is given a higher horsepower rating for a limited period of time. Continuous duty means that the motor could run 24 hours a day if all other factors are within specifications. Other ratings are: short-time duty, intermittent duty, periodic duty or varying duty. Within these classes there can be manufacturer established time ratings of 5, 15, 30 or 60 minutes. A short time rated motor is used in applications where sufficient rest time exists for the motor to cool down before it is likely to be used again. Examples wound be a garbage disposal or a crane. Identify the Enclosure Type of the motors available. List the type of enclosure for each motor on each page or index card. NEMA has classified motor enclosure types and defined them in accordance with the environment in which the motor operates. The two major groupings are Open or Totally
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Step 16.
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Enclosed. The open motors are best suited for clean environments and indoor service; motors that must operate outdoors, but still in a relatively clean environment use weather-protected open designs. Totally enclosed motors prevent the windings and rotor from being directly exposed to the external air. Totally enclosed motors find use in applications that are dirty, corrosive, or extremely wet. A fairly complex set of ratings exist for those enclosures considered ExplosionProof. Overall, the most common enclosure types are: ( 1) Open Enclosure - An open end frame structure that permits maximum air circulation. This construction is designed to prevent falling objects from making contact with electrically live or moving parts. - An open machine ( 2) Drip-Proof Enclosure construction that protects the motor from drops of liquid or solid particles striking the enclosure at angles from 0 to +/-15 degrees downward from the vertical plane. ( 3) Splash-Proof Enclosure - An open machine construction that protects the motor from drops of liquid or solid particles striking the enclosure at angles from 0 to +/-100 degrees downward from the vertical plane. ( 4) Guarded Enclosure - An enclosure arranged so that no accidental or intentional object can penetrate. ( 5) Weather-Protected Type 1 - An open construction that minimizes the entrance of rain, snow and air-borne particles. ( 6) Weather-Protected Type 2 - A construction that has intake and discharge ventilating passages that allow high velocity air and air-borne particles to bypass the motor internals. ( 7) Totally Enclosed Nonventilated (TENV) - A totally enclosed motor which is not equipped for cooling by means external to the enclosing parts. ( 8) Totally Enclosed Fan Cooled (TEFC) - A totally enclosed motor which is equipped for exterior cooling by means of a fan or fans integral with the motor but external to the enclosing parts. ( 9) Explosion Proof Motor - A totally enclosed motor construction that prevents the ignition of any gases or vapors surrounding the machine and contains sparks, flashes or explosions of specified gas or vapor
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occurring within the motor casing. (10) Dust Ignition Proof - A totally enclosed motor designed to exclude ignitable amounts of dust. It does not permit arcs, sparks, or heat generated inside the enclosure from igniting exterior accumulations or atmospheric suspensions of a specific dust. (11) Water Proof Enclosure - A totally enclosed motor so constructed that it excludes water from entering when applied in the form of a stream coming from a hose. Step 17. Identify the Locked-Rotor Code Letter of the motors available. List the locked rotor KVA per HP, if provided, for each motor on each page or index card. The code letter (found in NEC Article 430-7b for motors of HP or more) refers to the starting or locked rotor characteristics of the motor. These motors draw initial in-rush line currents that depend upon the construction of their rotors. This must be considered when providing overcurrent protection for the motor. Code Letters are listed as follows: Code Letters for Locked Rotors: Code Letter: A B C D E F G H J K L M N P R S
KVA/Horsepower with Locked Rotor: 0.00 - 3.14 3.15 - 3.54 3.55 - 3.99 4.00 - 4.49 4.50 - 4.99 5.00 - 5.59 5.60 - 6.29 6.30 - 7.09 7.10 - 7.99 8.00 - 8.99 9.00 - 9.99 10.00 - 11.19 11.20 - 12.49 12.50 - 13.99 14.00 - 15.99 16.00 - 17.99
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T U V
18.00 - 19.99 20.00 - 22.39 22.40 and up
Locked-rotor current values are used when sizing fuses or when determining a circuit breaker setting in an induction motor circuit. The circuit breakers instantaneous trip setting should be adjusted slightly above the locked-rotor current value in order to allow the motor to come up to speed properly. Step 18. Identify the NEMA Design Letter of the motors available. List the NEMA Design Letter for each motor on each page or index card. The NEMA Design Letter defines the starting torque characteristics of an induction motor. The load on a motor is essentially the torque required by the load. The formula for operating load torque is: 5252 x Horsepower (HP) Load Torque (ft.-lbs.) = ---------------------------------RPM However, two loads with the same load torque requirements at operating speed can have very different starting load torque requirements. Failure to take this rating into account when replacing a motor can lead to serious mis-applications. NEMA has designated 5 classes: Motor Characteristics by Rotor Design Class: NEMA Full-Load Start Torque Start Design Speed % X Rated Current Class Regulation Torque x Rated A B C 2- 5 3- 5 4- 5 1.5 - 1.75 1.4 - 1.60 2.0 - 2.50 5.0 - 7.0 4.5 - 5.0 3.5 - 5.0 Characteristic Name Normal Gen. Purpose Hi Torq. Double Cage
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D F Step 19.
5- 8 8 - 13 Over 5
Up to 3 1.25
3.0 - 8.0 2.0 - 4.0
Hi Torq., Hi Resistance
Identify the Power Factor of the AC motors available. List the Power Factor for each AC motor on each page or index card. The Power Factor of a motor is the ratio of true power used in watts and the apparent power delivered. It is expressed as a percentage. Note: Power Factor is not optimal at full rated voltage; the optimal Power Factor occurs at about 85% of rated voltage. Identify the Efficiency of the motors available, if provided. List the Efficiency for each motor on each page or index card. Efficiency is occasionally placed on the nameplates, and is expressed as a percent of output watts (horsepower watts) compared to input watts at full operating conditions. An efficiency rating of 85% means that 85% of the input electrical watts are converted to mechanical output watts or horsepower. The percent efficiency of any energy conversion system can be expressed as: Power OUT % Efficiency = ---------------------- x 100% Power IN No energy conversion is perfect, so the efficiency is always less than 100%. In the case of an electric motor the conversion is from electrical energy IN (Kwatts) to mechanical energy OUT (HP). Math relationships for this conversion are shown below: Horsepower OUT x 0.746 % Efficiency = -------------------------------------------- x 100% Kwatts IN and Power Out Power IN - Losses
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-------------Power IN
------------------------ x 100% Power IN
Summary
Congratulations! You have just demonstrated your ability to read the nameplates of a variety of motors. It is important for the maintenance electrician to have a complete understanding of how to read and interpret the nameplate of any motor they are called upon to service. Having acquired this skill an electrician will be able to perform more advanced motor maintenance and troubleshooting with increased confidence.
Optional Tasks
None.
Resources
National Fire Protection Association, National Electrical Code. Quincy, MA: 1984. Anderson, Edwin P., and Miller, Rex, Electric Motors. New York: Bobbs-Merrill Co. Inc., 1983. Bos, Michael H., and Brown, Michael V., Whats In A Name(Plate): A Practical Guide To AC Induction Motors. Milford, CT: New Standard Publishing, 1990. Putz, Herb, IPTs Electrical Training Manual. Edmonton, Alberta, Canada: IPT Publishing and Training, Ltd., 1994. Rosenberg, Robert, and Hand, August, Electric Motor Repair, 3rd Ed. Orlando, FL: Harcourt Brace Jovanovich, 1988.
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Interpreting Motor Nameplate Data: Exercise E410-S02.wpd

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Course 410-500 11/01/98

Industrial Motor Maintenance Exercise