Motors

Application of Induction
Motors with Variable
Frequency Drives

Ney E. T. Merheb
June 1999

1
1-1
 Motors
Introduction
l It is becoming very popular the utilization of squirrel cage
induction motors with variable frequency drives (VFD’s) in the
industry.
l The advance of power electronics technology and the cost of the
VFD’s are making this utilization possible.
l The many advantages of this type of application are:
Ù Speed variation.
Ù Heavy load inertia starting.
Ù High starting torque requirements.
Ù Low starting current requirements.
Ù High efficiency at low speed.
Ù High power factor.
l The induction motor with VFD’s replaces with advantage today
the DC motors, and wound rotor motors.
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 Motors
The Specification
l The utilization of VFD’s 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 VFD’s application:
ÙThe “Common Mode” Voltage
ÙHarmonics
ÙSwitching Frequencies and Stationary Waves
ÙSpeed Range
ÙStarting Aspects
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 Motors
The Speed Torque Curve
120 f e
n =
s
p

P (Hp) 5250 x P(Hp)

T = =
2 π fm 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)
dφ VM
v (t) = N ⇔ φ = cos ω t
dt ωN

® 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.

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 Motors
The Induction Motor Speed Torque Curve
240
Maximum Torque
220

200

180
Torque N.m

160

140

120 Starting Torque 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 6
 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 VFD’s allows the control of the torque
in all speed range automatically (requires tachometers) 7
 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

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 Motors
1.2

Motor Maximum Current Base Speed Constant Voltage Region

ð reduced DC motor field voltage region
1.0

Load Torque Curve

0.8
Motor Voltage in p.u.
Torque in p.u.

Co
nst
0.6 ne an
Li t Hp
z
s/H Lin
lt e
Vo
t
0.4 tan
s
on
C
Motor Voltage

Top Speed
0.2

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
VFD Lower Frequency Limit

Motor speed in p.u. of synchronous speed

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 Motors
1.50

1.25
Motor Voltage in p.u.

1.0
Torque in p.u.

Base Speed
Motor Torque
0.75
Line
z
ts/H
l
t Vo
n
0.5 nsta
Co

Load Torque
0.25

0.2 0.4 0.6 0.8 1.0

Motor Speed in p.u. 11
 Motors
2.0

1.66
Motor Voltage in p.u.

1.33
Torque in p.u.

Load Torque
1.0

Base Speed
0.66
z
Volts Boost Volts/H
t
stan
Con

0.33

0.2 0.4 0.6 0.8 1.0

Motor Speed in p.u.
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 Motors
750 HP Motor - 6 Poles - 540 rpm base speed - 575 V
8750

Max. Motor Current at 345 V 540 rpm Constant Volts = 575 V

7292

Constant Torque region

5833
Torque in lb-ft

ne 75
4375 Li 0
HP HP
z
s/H reg Con
lt ion sta
Vo nt
t
tan
2917 s
on
C
Volts

1458 Top Speed

180 360 540 720 900 1080 1260 1440 1620 1800
9 18 27 36 45 54 63 72 81 90
Speed in rpm
Frequency in Hz
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 Motors
500 HP Motor - 6 P 1440 rpm 2300 V
2734

2278

1823 2300 V
Torque in lb-ft

72 Hz
Motor Torque

1367
z
lts/H
o
ntV
ta
911 ons
C

Load Torque
455

288 576 864 1152 1440

14.4 28.8 43.2 57.6 72
Speed in rpm
Frequency in Hz
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 Motors

5KAF
400HP KAF TEAO
1200 6811
368 SKF 6319
575 575 GREASE
40
0.9567 0.85 SKF 6319
1.15 1.0 GREASE
F
80
CONTINUOUS
IGBT-PWM 40
1000
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. 16
 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 VFD’s 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 µs.
l Requirements for medium voltage motors is still not normalized but
GE follows IEEE 522.
l The high speed switching VFD’s 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

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 Motors
The Insulation System

The Waveforms and Harmonics

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 Motors
The Insulation System

The Voltage Spikes

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The Mechanical System

l The operation with VFD’s will require the examination of the
critical features of the motor, as such:

èCritical speeds
èMaximum operation speed
èBearing lubrication
èVentilation and cooling
èInsulation of the bearings against current circulation
èShaft grounding brushes

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 Motors
The Mechanical System
l Mechanical protection and cooling arrangements most utilized
in VFD’s 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

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 Motors

The Mechanical System

DPBV (Drip Proof Blower Ventilated) IP23 - IC06

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 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 VFD’s operation
are:

2 Tachometers ( specially for vector control drives) to be used

when speed control is critical.
2 Winding temperature sensors as such RTD’s or Thermistor
for temperature monitoring.
2 Shaft grounding brushes (depending on VFD’s 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 Serviço _____
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 VFD’s.

• The low voltage windings are special to meet the requirements of NEMA
MG1 - 31 for use with VFD’s.

• 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. 32
 Motors
Some KAF motors furnished
CUSTOMER COUNTRY TYPE HP VOLTS POLES ENCLOSURE

JEN AN STEEL TAIWAN KAF 800 575 6 TEAO

JEN AN STEEL TAIWAN KAF 804 575 6 TEAO
JEN AN STEEL TAIWAN KAF 1207 575 6 TEAO
USIMINAS BRAZIL KAF 603 460 12 WPII
USIMINAS BRAZIL KAF 480 460 6 WPII
AK STEEL USA KAF 1178 440 6 TEFV
AK STEEL USA KAF 800 440 6 TEFV
NUCOR USA KAF 1125 575 4 WPII
NUCOR USA KAF 950 575 4 WPII
NSM THAILAND KAF 1350 575 6 TEFV
NSM THAILAND KAF 500 575 6 TEFV
CYPRESS CREEK USA KAF 1250 4160 8 TEFV
HOOGOVENS HOLAND KAF 1126 3300 12 TEFV
HOOGOVENS HOLAND KAF 80 400 24 WPII
HOOGOVENS HOLAND KAF 635 400 6 WPII
CHAPARRAL STEEL USA TSAF 1500 3300 4 TEFV
CHAPARRAL STEEL USA TSAF 1200 3300 8 TEWAC
CHAPARRAL STEEL USA TSAF 3352 3300 26 TEWAC
CHAPARRAL STEEL USA TSAF 3352 3300 12 TEWAC
CHAPARRAL STEEL USA TSAF 7375 3300 20 TEWAC

TSAF = Synchronous Motor

KAF = Squirrel Cage Induction Motor
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