Motors

Application of Induction
Motors with Variable
Frequency Drives
Ney E. T. Merheb
June 1999

1-1

Motors

Introduction
l It is becoming very popular the utilization of squirrel cage
induction motors with variable frequency drives (VFDs) in the
industry.
l The advance of power electronics technology and the cost of the
VFDs are making this utilization possible.
l The many advantages of this type of application are:
Speed variation.
Heavy load inertia starting.
High starting torque requirements.
Low starting current requirements.
High efficiency at low speed.
High power factor.

l The induction motor with VFDs replaces with advantage today

the DC motors, and wound rotor motors.
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Motors

The Specification
l The utilization of VFDs may affect the design, performance
and reliability of induction motors. Some effects are positive
like the less fatigue to the mechanical components and rotating
elements due to soft speed variation.
l The life of the motors can be influenced positively when
adequately applied.
l There are some important factor to be considered when
specifying motors with VFDs application:
The Common Mode Voltage
Harmonics
Switching Frequencies and Stationary Waves
Speed Range
Starting Aspects
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Motors

The Speed Torque Curve

n

120 f e
p
P (Hp)

2 fm

5250 x P(Hp)
=
nm

The synchronous speed of the motor varies linearly with the electrical

frequency and inversely with the number of poles.

For a given Torque the Shaft Power varies linearly with the speed (n).
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Motors

The Voltage over Frequency Curve

(V/Hz)
d
v (t) = N
dt

VM
N

cos t

The Maximum torque of the motor varies with the square of the flux

(or V/Hz relation).

On the constant voltage region the maximum torque decreases with

he square of the V/Hz relation.

Motors

The Induction Motor Speed Torque Curve

240
Maximum Torque

220

Torque N.m

200
180
160
140
Starting Torque

120

Full Load Torque

100
80
60
40
20
0
0

100

200

300 400

500 600 700 800 900 1000 1100 1200 1300 1400

Speed rpm

Motors

Defining the Motor - The Operating Points

l The motor design is based on the load speed torque curve.
l Check the operating points.
l Motor voltage should be limited to its nominal volts.
l Maximum current occurs at base speed. (VFD sizing and
selection).
l Scalar type inverters allows the adjustment of the V/Hz curve.
l Use of voltage boosting at low speed to increase the starting
torque.
l The use of vector control VFDs allows the control of the torque
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in all speed range automatically (requires tachometers)

Motors

Some Examples
l Constant Torque applications
l Steel mills machines, Paper machines (winder, tension reels, mill
stands)
l Cement mills, rubber mills, mixers, crushers
l Conveyors
l Cranes and elevators cars

l Variable Torque applications:

l Centrifugal pumps
l Centrifugal fans
l Compressors
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Motors

Some Examples

Motors
1.2
Motor Maximum Current

Constant Voltage Region

Base Speed

reduced DC motor field voltage region

1.0
Load Torque Curve
Motor Voltage in p.u.
Torque in p.u.

0.8

0.6

0.4

t
an
t
s
on
C

z
/H
s
lt
Vo

Co
nst
an
t

ne
Li

Hp
Lin
e

Motor Voltage

Top Speed

0.2

0.1
0.2
0.3
VFD Lower Frequency Limit

0.4

0.5

0.6

0.7

0.8

0.9

1.0

Motor speed in p.u. of synchronous speed

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Motors
1.50

1.0

Torque in p.u.

Motor Voltage in p.u.

1.25

Base Speed

Motor Torque
0.75

ine
L
z
/H
s
t
l
Vo
t
n
sta
n
Co

0.5

Load Torque
0.25

0.2

0.4

0.6

Motor Speed in p.u.

0.8

1.0

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Motors
2.0

1.33

Torque in p.u.

Motor Voltage in p.u.

1.66

Load Torque
1.0

Base Speed
0.66
z
lts/H
o
V
t
stan
Con

Volts Boost

0.33

0.2

0.4

0.6

Motor Speed in p.u.

0.8

1.0

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Motors
750 HP Motor - 6 Poles - 540 rpm base speed - 575 V
8750
Max. Motor Current at 345 V

Constant Volts = 575 V

540 rpm

7292
Constant Torque region

Torque in lb-ft

5833

4375
t
an
t
s
on
C

2917

z
/H
s
lt
Vo

ne
Li

75
0
HP HP
reg Con
ion sta
nt

Volts

1458

Top Speed

180
9

360
18

540
27

720
36

900
45

1080
54

1260
63

1440
72

1620
81

1800
90

Speed in rpm
Frequency in Hz
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Motors
500 HP Motor - 6 P 1440 rpm 2300 V
2734

Torque in lb-ft

2278

2300 V
72 Hz

1823

Motor Torque
1367
z
s/H
t
l
o
tV
n
ta
ns
o
C

911

Load Torque
455

288
14.4

576
28.8

864
43.2

1152
57.6

1440
72

Speed in rpm
Frequency in Hz
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Motors
5KAF
400HP
1200
368
575
0.9567
1.15

KAF

TEAO
6811
SKF 6319
GREASE

575
40
0.85
1.0

SKF 6319
GREASE

F
80
CONTINUOUS
IGBT-PWM
1000

40
120
1200

1200
1800

1200

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Motors

The Overload
l Normally the overload is specified at base speed.
l The overload occur in short period of time (60 seconds).
l Standard overload requirements is in the range of 150 to 200%.
It depends on the application.
l The motor must have sufficient maximum torque to hold the
overload conditions.
l The motor will give the maximum current at the base speed. It
is based on this current that the VFD must be selected.
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Motors

The Motor Heating

l The VFD normally produces harmonics that can cause
additional overheating to the motor. The engineer will have to
consider them when designing the motor.
l Some VFD manufactures guarantee that their VFD do not
produces harmful harmonics to the motor.
l In constant torque application it is necessary to provide
additional ventilation to the motor to provide cooling at low
speeds. A motor-blower can be used or external forced
ventilation.
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Motors

The Motor Heating

l Variable torque applications like centrifugal fans and pumps it
is not required to use additional ventilation as the power is
reduced by the cubic of the speed.
l The harmonics can also induce additional heat to the rotor cage
so, the across the line torque can be affected (double cage should
be avoided).
l Frequencies too high should be avoided due to increase of motor
losses (higher than 100 Hz). The number of poles should be
selected accordingly.
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Motors

The Insulation System

l The VFDs in general produces voltage spikes that will affect the
insulation of windings if they are not prepared for it.
l The NEMA MG1 - Part 31 Std. , requires that the low voltage motor
winding must be capable to withstand up to 1600 peak Volts with a
rise time of 0.1 s.
l Requirements for medium voltage motors is still not normalized but
GE follows IEEE 522.
l The high speed switching VFDs as the (IGCT ou IGBT) normally
produces high frequency dV/dt that may fatigue the winding
insulation. The Multi-Level PWM system or filters will prevent high
induced voltage to the winding.
l The insulation system should be adequate to this voltage.
l Example: Nominal Voltage 4160 V, Insulation System Voltage 5000 V.
l Cabling length can affect the terminal voltage (RC Filters).
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Motors

The Insulation System

Typical Low Voltage Winding

20

Motors

The Insulation System

The Waveforms and Harmonics

21

Motors

The Insulation System

The Voltage Spikes

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Motors

The Mechanical System

l The operation with VFDs will require the examination of the
critical features of the motor, as such:
Critical speeds
Maximum operation speed
Bearing lubrication
Ventilation and cooling
Insulation of the bearings against current circulation
Shaft grounding brushes
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Motors

The Mechanical System

l Mechanical protection and cooling arrangements most utilized
in VFDs applications (specially constant torque):
l DPBV (Drip Proof Blower Ventilated) IP23 - IC06
l DPSV (Drip Proof Separately Ventilated) IP23 - IC06
l TEFC (Totally Enclosed Fan Cooled) IP54 - IC411
l TEAO ( Totally Enclosed Air Over) IP54 - IC416
l WPII - with blower IPW24 - IC06
l TEWAC - with blower IP54 - IC86W
l TEFV (Totally Enclosed Forced Ventilated) IP54 - IC37
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Motors

The Mechanical System

TEAO ( Totally Enclosed Air Over) IP54 - IC416

25

Motors

The Mechanical System

DPBV (Drip Proof Blower Ventilated) IP23 - IC06

26

Motors

The Mechanical System

DPSV (Drip Proof Separately Ventilated) IP23 - IC06

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Motors

The Accessories
l The most common accessories on motors for VFDs operation
are:
2 Tachometers ( specially for vector control drives) to be used
when speed control is critical.
2 Winding temperature sensors as such RTDs or Thermistor
for temperature monitoring.
2 Shaft grounding brushes (depending on VFDs type)

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Motors

The Accessories

A TEFC Motor with Digital

Tachometer
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Motors

Specifying the Motor

l In the next page we summarize all the main information
to be sent to the motor supplier when specifying a
induction motor in use with a VFD application. This
data will help the motor design or application engineer
to correctly select the motor for the application.

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Motors
KAF INDUCTION MOTOR BASIC SPECIFICATION
Shaft Power (in HP, or KW) ___________________
Enclosure _______ ; Insulation F; Ambient Temperature ____ C
Temperature rise _____ no Fator de Servio _____
RPM base _____________ RPM max (top speed)_____________
RPM minimum in operation________
Application (Driven Machine) ______________________
Torque below base speed:
Variable Torque _____ Constant Torque ______
Volts __________
Starting across the line capability: Yes or No _____
VFD Type:
_____ PWM ______ IGBT or IGCT
______ GTO
_____ CSI
Name of VFD Manufacturer (if available) _______________________
Overload at base speed:
_____ 150% current (standard)
_____ 200% current
Service Factor with the VFD __________ (1.0 standard or 1.15)
Bearings: Anti-friction _______ Sleeve ______ Manufacturer standard _________
Tachometer: Yes_____ No _______
Model _____________ Provision for __________
Thermal Sensor on windings :
RTD Pt 100 ohms____ Cu 10 ohms _____
Thermistor ___________
Other accessories _________________________
GE - GEVISA S.A.

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Motors

The GEIS- GEVISA Experience

GEIS participate on all markets which the motors with VFD is present
GE-GEVISA as a world wide supplier for the GEIS system has
manufactured more than 700 units of low voltage and medium voltage
motors for many different VFD applications.
Experience with all applications and configurations with many different
drives types and manufactures.
The regular medium and high voltage (2300 to 13800 V) insulation
system is adequate for all systems. There is no need for modifications for
use with VFDs.
The low voltage windings are special to meet the requirements of NEMA
MG1 - 31 for use with VFDs.
GE-GEVISA has an Application Engineering team all prepared to give
the assistance to customer to help with the specification and selection of the
most adequate motor for the application.

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Motors

Some KAF motors furnished

CUSTOMER
JEN AN STEEL
JEN AN STEEL
JEN AN STEEL
USIMINAS
USIMINAS
AK STEEL
AK STEEL
NUCOR
NUCOR
NSM
NSM
CYPRESS CREEK
HOOGOVENS
HOOGOVENS
HOOGOVENS
CHAPARRAL STEEL
CHAPARRAL STEEL
CHAPARRAL STEEL
CHAPARRAL STEEL
CHAPARRAL STEEL

COUNTRY TYPE

HP

TAIWAN
TAIWAN
TAIWAN
BRAZIL
BRAZIL
USA
USA
USA
USA
THAILAND
THAILAND
USA
HOLAND
HOLAND
HOLAND
USA
USA
USA
USA
USA

800
804
1207
603
480
1178
800
1125
950
1350
500
1250
1126
80
635
1500
1200
3352
3352
7375

KAF
KAF
KAF
KAF
KAF
KAF
KAF
KAF
KAF
KAF
KAF
KAF
KAF
KAF
KAF
TSAF
TSAF
TSAF
TSAF
TSAF

VOLTS POLES ENCLOSURE

575
575
575
460
460
440
440
575
575
575
575
4160
3300
400
400
3300
3300
3300
3300
3300

6
6
6
12
6
6
6
4
4
6
6
8
12
24
6
4
8
26
12
20

TEAO
TEAO
TEAO
WPII
WPII
TEFV
TEFV
WPII
WPII
TEFV
TEFV
TEFV
TEFV
WPII
WPII
TEFV
TEWAC
TEWAC
TEWAC
TEWAC

TSAF = Synchronous Motor

KAF = Squirrel Cage Induction Motor

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