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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.
2
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
3
Motors
The Speed Torque Curve
120 f e
n =
s
p
® 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).
4
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).
5
Motors
The Induction Motor Speed Torque Curve
240
Maximum Torque
220
200
180
Torque N.m
160
140
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 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
8
Motors
Some Examples
9
Motors
1.2
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
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
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
7292
ne 75
4375 Li 0
HP HP
z
s/H reg Con
lt ion sta
Vo nt
t
tan
2917 s
on
C
Volts
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
13
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
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
15
Motors
The Overload
l Normally the overload is specified at base speed.
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.
17
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).
18
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).
19
Motors
The Insulation System
21
Motors
The Insulation System
22
Motors
èCritical speeds
èMaximum operation speed
èBearing lubrication
èVentilation and cooling
èInsulation of the bearings against current circulation
èShaft grounding brushes
23
Motors
The Mechanical System
l Mechanical protection and cooling arrangements most utilized
in VFD’s applications (specially constant torque):
24
Motors
25
Motors
26
Motors
27
Motors
The Accessories
l The most common accessories on motors for VFD’s operation
are:
28
Motors
The Accessories
30
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.
31
Motors
The GEIS- GEVISA Experience
• GEIS participate on all markets which the motors with VFD is present
• The low voltage windings are special to meet the requirements of NEMA
MG1 - 31 for use with VFD’s.