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ABB Ltd

Application Advice

Selecting a VSD when using an Over sized motor


Author

F.T.Griffith

Applications Group

Date

05/07/2011

Introduction In the past switchgear, contactors etc, were rated to match the current (power) of the associated motor. This ensured that there was always sufficient thermal margin in the starter components to cater for any variations in actual running duty. The fact that the actual running duty may have been less than the rating of the motor was of no real consequence since the cost of matching switchgear components to the reduced rating did not yield any real cost benefit. It is natural to apply this same rating philosophy to Variable Speed Drive (VSD) controlled motors. However, this can result in accepting a cost premium which is not really a requirement , especially if the reduced running duty is not expected to change. VSDs are rated according to CURRENT not Power, so, where a fully rated motor operates at reduced duty, then advantage can be taken of using a lower rated VSD (based on operating current rather than motor RATED current). This note shows by example how the selection of a lower rated VSD can be of benefit. Method The example chosen is a screw compressor rated at 450kW @ 1500 RPM which has operating Duty points of 350kW, 200kW & 100kW respectively. For all of the cases the 450kW 4 pole motor is retained. Using the DRIVESIZE programme first the motor was selected for a Constant torque load, corresponding to 350kW @ 1500RPM, using this motor data individual inverters were selected for Duty points of 350kW,200kW & 100kW respectively. The results are shown in the table (next page) below. The 100kW duty point has two selections for an inverter, the first is one being run at its absolute maximum which, although the smallest inverter size, would not be recommended. All of the inverter selections are smaller than the inverter size that would have been chosen based upon the motor rating. The inverter selected for a motor rated Duty point would have been a 610-3 (610kVA rated : 500kW) unit. In comparison the selected inverters are as listed below ; 1) 2) 3) 350kW Duty : 440-3 (440kVArated, 355kW) 200kW Duty : 260-3 (260kVArated, 200kW) 100kW Duty : 260-3 (260kVArated, 200kW) or 205-3 (205kVArated, 160kW)

ABB Ltd

Application Advice

Selecting a VSD when using an Over sized motor


Author

F.T.Griffith

Applications Group

Date

05/07/2011

Project Technical Data Sheet


File name: Case: Revision: Item No. 1.1.1 1.1.2 1.1.3 1.1.4 350kW 100kW 200kW 100kW Undersize motor 1 A Drive name Speed range min base max [rpm] [rpm] [rpm] Duty 300 1500 1500 Duty Smallest Inverter 300 1500 1500 Duty 300 1500 1500 Duty Larger Inverter 300 1500 1500

P [nbase] [kW] 350 100 200 100

Type designation M3BP 355 MLB 4 M3BP 355 MLB 4 M3BP 355 MLB 4 M3BP 355 MLB 4

Motor nominal values Un fwp Pn Poles [V] [Hz] [kW] 400 50 450 4 400 50 450 4 400 50 450 4 400 50 450 4

In [A] 780 780 780 780

cos phi 0.86 0.86 0.86 0.86

eff. Tmax [%] /Tn 97 2.9 97 2.9 97 2.9 97 2.9

Temp.rise/ Insul. B/F B/F B/F B/F

Motor calculation result Tcont Tmax Icont margin margin [A] 4% 119% 665 263% 668% 321 81% 284% 431 263% 668% 321

Imax [A] 665 321 431 321

Frequency converter In Type designation [A] ACS800-02-0440-3 679 ACS800-01-0205-3 285 ACS800-02-0260-3 440 ACS800-02-0260-3 440

Inu calculation Icont Imax margin margin 4% 53% -10% 9% 3% 36% 39% 83%

Conclusion From the short description above it can be seen that lower rated inverters can be chosen to operate with a larger rated motor , than that of the selected Duty point, As such this shows that where a lower Duty point power is required and using a higher rated motor, say, for mechanical reasons, it is not necessary to select a fully rated inverter for a Duty related to motor rating. F.T.Griffith Applications Group

Note : Technical charts and data from the DRIVESIZE programme shown in the Appendix.

ABB Ltd

Application Advice

Selecting a VSD when using an Over sized motor


Author

F.T.Griffith

Applications Group

Date

05/07/2011

Appendix
Motor Technical Data Sheet
Item No. 1.1.1 Specifications Name [undefined] No.of motors 1 Motor type Process performance FrameMaterial Not specified Family Not specified Polenumber 4 Design Basic (Cenelec) Connection Not specified IP class IP55 IC class IC411 self ventilated IM class IM1001, B3(foot) Max. speed rule Standard Temp. rise B (<80 K) Tmax margin 43% Motor load Calculations Load type Constant torque Torque [Nm] Overload Type Simple n min n min [rpm] 300 n base n base [rpm] 1500 Power [kW] n max [rpm] 1500 n min Pbase [kW] 350 n base Olbase [%] 100 Overload [Nm] Olmax [%] 100 n min Temperature [ C] 40 n base Altitude [m] 1000 Ol definition: No RMS 300-1500 rpm / 100 % 590s 300-1500 rpm / 100 % 10s

M3BP 355 MLB 4


DOL Catalogue data Product code Voltage [V] Frequency [Hz] Power [kW] Poles Speed [rpm] Max mech.speed [rpm] Current [A] Torque [Nm] Tmax/Tn Power factor Efficiency [%] Temperature rise class Insulation class 3GBP 352 420 (FI) 400 50 450 4 1490 2000 780 2884 2.9 0.86 96.8 B F

2228 2228 70 350 2228 2228

2313 2579 72.7 405 5855 4889

4% 16 % 4% 16 % 163 % 119 %

Motor data

ABB Ltd

Application Advice

Selecting a VSD when using an Over sized motor


Author

F.T.Griffith

Applications Group

Date

05/07/2011

Drive Technical Data Sheet


1.1.1 Item No. Specifications Name Inverter amount Type Pulse

ACS800-02-0440-3
Catalogue data [undefined] 1 Auto selection 6-pulse Voltage [V] Nominal power [kW] Nominal current [A] Imax [A] Ihd [A] Pulse Frame type Icont max [A] IP Class 400 355 679 1017 590 6 R8 693 IP21

Inverter load Load type Overload type Icont [A] Imax [A] cosfii

Constant torque Simple cyclic 665 590s 665 10s

Calculations Limit Icont [A] Imax [A] Pmax kW Temperature

665 665 362

693 1017 474

4% 53 % 31 % 6%

Selection method: IGBT temperature

300kW Duty Inverter

ABB Ltd

Application Advice

Selecting a VSD when using an Over sized motor


Author

F.T.Griffith

Applications Group

Date

05/07/2011

Drive Technical Data Sheet


1.1.3 Item No. Specifications Name Inverter amount Type Pulse

ACS800-02-0260-3
Catalogue data [undefined] 1 Auto selection 6-pulse Voltage [V] Nominal power [kW] Nominal current [A] Imax [A] Ihd [A] Pulse Frame type Icont max [A] IP Class 400 200 440 588 340 6 R8 445 IP21

Inverter load Load type Overload type Icont [A] Imax [A] cosfii

Constant torque Simple cyclic 431 590s 431 10s

Calculations Limit Icont [A] Imax [A] Pmax kW Temperature

431 431 207

445 588 241

3% 36 % 17 % 4%

Selection method: IGBT temperature

200kW & 100kW Duty Inverter

ABB Ltd

Application Advice

Selecting a VSD when using an Over sized motor


Author

F.T.Griffith

Applications Group

Date

05/07/2011

Drive Technical Data Sheet


1.1.2 Item No. Specifications Name Inverter amount Type Pulse

ACS800-01-0205-3
Catalogue data [undefined] 1 Auto selection 6-pulse Voltage [V] Nominal power [kW] Nominal current [A] Imax [A] Ihd [A] Pulse Frame type Icont max [A] IP Class 400 160 285 351 234 6 R6 290 IP21

Inverter load Load type Overload type Icont [A] Imax [A] cosfii

Constant torque Simple cyclic 321 590s 321 10s

Calculations Limit Icont [A] Imax [A] Pmax kW Temperature

321 321 103

290 351 212

-10 % 9% 105 % 4%

Selection method: IGBT temperature

100kW Duty Inverter

ABB Ltd

Application Advice

Selecting a VSD when using an Over sized motor


Author

F.T.Griffith

Applications Group

Date

05/07/2011

3500

3000

2500

Torque [N m ]

2000

1500

1000

500
Speed [rpm]

0 0 200 400 cont loadability 600 100kW 800 1000 200 kW 1200 350 kW 1400 1600

Fig 1 : Operating Torque for differing Duty power

ABB Ltd

Application Advice

Selecting a VSD when using an Over sized motor


Author

F.T.Griffith

Applications Group

Date

05/07/2011

800

700

600

500
Torque [Nm ]

400

300

200

100
Speed [rpm]

0 0 200 440-3 400 260-3 600 205-3 800 260-3 1000 350 kW 1200 200 kW 1400 100kW 1600

Fig 2 : Operating Current for differing Duty power