Three steps to size

motors
Proper motor sizing precludes equipment failures,
ensures efficiency and reduces maintenance issues.

Courtesy: AutomationDirect

Electric motors are a primary means for furnishing motion on modern industrial
machinery and equipment, but designers cannot bolt on the cheapest version that fits.
Implemented properly, electric motors are a cost-effective and reliable method to create
rotational motion, and they also can couple with gearboxes and other mechanisms to
achieve varying levels and types of force. Motors that are not properly sized will be
inefficient and can cause operational and maintenance problems.

Designers are, at times, overwhelmed by the wide variety of motor manufacturers, styles
and sizes available. Typical motors may be ac or dc, for fixed or variable speed, with
steppers and servos as options for high-precision applications. Each style has certain
strengths, but all applications must be sized to operate the load under all normal
conditions. The focus of this article is on basic ac motors (see Figure 1).
 Figure 1: Most industrial machinery or equipment incorporates multiple ac motors.
Courtesy: AutomationDirect

look at the requirements. For any machine builder or OEM, cost is always a key
consideration. Beyond that, an evaluation of the environmental conditions, operational
requirements and available power will lead users down the right path. This article
reviews the basic considerations and steps for properly selecting and sizing electric
motors.

Benefits of getting the right motor

Getting the motor size right is critical for any application. Properly sized motors operate
the driven equipment most efficiently, which in turn causes the least wear and tear.
When equipment is running correctly, machine uptime is maximized, and so is the return
on investment in the motor and the driven equipment.

Energy efficiency is another big factor. Beginning in the 1990s, regulations have
progressively required more motor types of 1.0 hp and above to deliver better
efficiencies. Refined designs and construction methods using more copper allow these
premium-efficiency motors to draw less current in operation. Initial costs are usually
higher, typically more than offset by lower operating costs over the life of the motor.

Heat and installation issues are two main reasons for motor failure, so both conditions
must be considered. Heat can originate from several sources and is most damaging to
motor insulation systems. It can arise from outdoor installations, or it can be transmitted
from associated process equipment.
Electric motors generate their own heat within the windings during operation, and
mechanical friction at motor bearings is another source. Installation issues such as
misalignment, improper cooling, incorrect motor type for the environment and vibration
must be corrected. Properly sized motors will not experience problematic heat due to
overloading, and excess heat can be mitigated by ensuring proper cooling with adequate
available airflow.

Improper installation resulting in misalignment and or excess vibration will mechanically

damage the motor, bearings and associated equipment over time. Motors must be
correctly installed and sufficiently sized for the applied loading to minimize and to
mitigate vibration issues and ensure long bearing life. Proper selection of motor
mounting brackets can simplify installation and assist in accomplishing correct
alignment.

Steps for motor sizing

The process for sizing motors for an application breaks down into three major steps:

 Investigating the load operating characteristics

 Considering the operational environment
 Planning for the available power supply.

Motor sizing steps should generally be performed in this order, but each factor relates to
and affects the others. Properly accounting for these considerations and selecting a
motor based on them results in selecting a motor that can carry out the work needed
without having a shortened life due to premature winding, insulation or bearing damage.

A motor’s primary job is to continue spinning at a commanded speed regardless of the

torque load so it can deliver the necessary amount of mechanical power. The motor
must overcome the load’s inertia, or resistance to movement, to accelerate to the
desired speed, and then maintain it. Not every motor load is the same, however.
 Figure 2: Material handling conveyors are a common constant-torque application well-
suited to ac motors. Courtesy: AutomationDirect

Constant torque loads are the most straightforward applications. These are loads where
the required torque does not vary much with the speed. This is common for conveyors,
compressors and cranes (see Figure 2). The horsepower requirement does vary with
speed or how much work is effectively being performed. For these constant torque
applications, it is necessary to determine the load experienced by the motor in order to
select the proper horsepower. This may be indicated on the nameplate of the driven
machine, or from torque testing to determine the amount of required force. The minimum
required horsepower is calculated using the formula:
Variable torque loads, where the required torque changes with speed, are more
characteristic of equipment like pumps and fans. These loads should be sized to the
highest or peak loading.

For any motor load, one must account for the fixed operational speed or the variable
speed range at which the motor will run when connected to the equipment. Variable
frequency drives for adjusting motor speed are a good option, especially since many
loads will experience large decreases in energy usage if the motor can be run at a
slower speed. For variable speed applications, the turndown ratio of the motor and
equipment must be evaluated. This ratio is the maximum or nominal motor full speed
divided by the lowest operating speed. A motor may lose the capability to cool itself if
turned down too far. For motors that will use a variable frequency drive, ensure that the
motor selected is a 3-phase inverter-duty-rated motor.

Duty cycle of the load defines how much time the motor must run and stop. The motor’s
rated duty cycle must be better than that required by the load. Frequent starts are harder
on a motor because they generate more heat. A motor with a duty cycle rating of less
than 100% or continuous will be smaller and less expensive, but it must be operated
with rest cycles to offload the heat buildup. In many applications, specifying a 100% duty
cycle motor is prudent.

Consider the environment

Environmental considerations include the maximum and minimum ambient
temperatures, normal and washdown moisture and contaminants such as dust and dirt.
These will drive selection of the motor construction type. There are many configurations
to meet various environments, and three popular styles for industrial applications are:

 Open drip-proof (ODP): Relatively open enclosure promotes cooling but

requires an indoor, relatively clean and dry location; protected against falling
water.
 Totally enclosed fan-cooled (TEFC): Enclosed but not completely air-tight
enclosure, often with a ribbed frame to aid with cooling; provided with an external
fan; versatile motor for most locations.
 Totally enclosed blower-cooled (TEBC): Like TEFC, but is provided with a
separately driven external blower to keep the motor cool even when operating at
low speeds where an integrated fan would be ineffective.

Best practice is to choose the motor able to withstand the operating environment with
the best cooling performance. This will increase uptime, extend operational life and
reduce required maintenance.

Plan for available power supply

The available power supply and preferred motor controls also play a role in sizing the
motors for an application. For ac motors, users will need to select a single-phase or a 3-
phase motor based on what is available at the facility. Generally speaking, 3-phase
power is better suited for machine and process applications. Also, the higher the
operating voltage, the lower the electrical current needed for the same load, and lower
current uses thinner conductors and generates less heat. Common electrical
connections for industrial ac motors are 120 V c single-phase, 230 Vac single-phase and
240/480 Vac 3-phase.

Selecting the operating voltage often comes down to using what is commonly available
at a given location. But where there is a choice, a higher operating voltage improves
motor longevity. This is particularly important in smaller motors where the mass, fan
construction and insulation systems may not adequately offload heat. A 3-phase motor
is more easily reversed than a single-phase motor and is thus preferred for applications
requiring forward and reverse operation.

Typical applications
Following are typical applications and corresponding suitable motor sizing choices:

 Single-phase or 3-phase ODP motors:

Typical uses include machine tools, conveyors, packaging machines, batching
machines, food and beverage equipment, pumps, fans and air compressors.
 3-phase TEFC motors:
Typical applications are the same as for ODB motors, but these should be used
where wet or dirty conditions are encountered.
 NEMA premium efficiency inverter duty TEBC motors:
Typical uses include gear reducers, pumps, machine tools and other direct-
coupled equipment installed in damp, dusty or dirty environments where long life
and ultra-high efficiency is required.
 Jet pump motors (these motors have special seals, shaft material and designs):
Typical uses include jet pumps, well pumps and other liquid pumping
applications.

Successful motor sizing strikes a balance

Following the steps presented in this article will ensure a motor will be sized for all load
conditions, able to survive the environment and functionally match the available power.
There are often multiple sizing and other options for a motor application, and a
successful design will strike the best balance among these options while minimizing
initial and operational costs.