Course 410-500 Industrial Motor Maintenance

11/01/98 Exercise
1998 Design Assistance Corporation 02-1
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, #562-
MAN)
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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Figure 1 DAC #410 Split Phase, Capacitor-
Start AC Motor Nameplate
Performance Steps
Step 1. Identify the basic terms and types of information found on the
typical motor nameplate.
Identify the information listed on typical motor nameplates.
Manufacturer Phase/Frequency NEMA Design Letter
Type or Style Service Factor KVA Code Letter
Frame Size Insulation Class Efficiency
Rated Power (HP) Ambient Temp. Power Factor
Rated Voltage Rated RPM/Speed Enclosure Type
Full Load Amperage Duty or Time Connection Diagrams
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
Figure 2 DAC #412 Three-Phase,
Capacitor-Start AC Motor Nameplate
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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.
Step 2. 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.
Step 3. 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.
Step 4. Identify the Frame Size of the motors available.
List the Frame Number on each page or index card.
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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.
Step 5. 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:
F x R x N 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 Rated
System Motor
Voltage Voltages
216 Volts 208 Volts
240 230
480 460
600 575
2400 2300
4160 4000
4800 4600
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 110% of 120% of
Voltage Voltage Voltage
Full Load Current 11% 7% 11%
Increase Decrease Decrease
Full Load Speed 1% 1/2% 1%
Decrease Increase Increase
Starting Torque 19% 21% 44%
Decrease Increase Increase
Starting Current 10% 10% 20%
Decrease Increase Increase
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.
Step 7. 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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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.
Step 9. 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
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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.
Step 12. 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.
Step 14. 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 Ambient Temp. Hot Spot Hot Spot
Centigrade: Temp. Rise Allowance Temp.
Class A - 40 40 40 40
Class B - 60 80 105 125
Class F - 5 10 10 15
Class H - 105 130 155 180
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.
Step 16. 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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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 Explosion-
Proof. 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.
( 2) Drip-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 +/-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 KVA/Horsepower
Letter: with Locked Rotor:
A 0.00 - 3.14
B 3.15 - 3.54
C 3.55 - 3.99
D 4.00 - 4.49
E 4.50 - 4.99
F 5.00 - 5.59
G 5.60 - 6.29
H 6.30 - 7.09
J 7.10 - 7.99
K 8.00 - 8.99
L 9.00 - 9.99
M 10.00 - 11.19
N 11.20 - 12.49
P 12.50 - 13.99
R 14.00 - 15.99
S 16.00 - 17.99
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T 18.00 - 19.99
U 20.00 - 22.39
V 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 Characteristic
Design Speed % X Rated Current Name
Class Regulation Torque x Rated
A 2 - 5 1.5 - 1.75 5.0 - 7.0 Normal
B 3 - 5 1.4 - 1.60 4.5 - 5.0 Gen. Purpose
C 4 - 5 2.0 - 2.50 3.5 - 5.0 Hi Torq. Double
Cage
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D 5 - 8 Up to 3 3.0 - 8.0 Hi Torq.,
8 - 13 Hi Resistance
F Over 5 1.25 2.0 - 4.0
Step 19. 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.
Step 20. 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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-------------- = ------------------------ x 100%
Power IN 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, 3
rd
Ed. Orlando, FL:
Harcourt Brace Jovanovich, 1988.