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Copyright © 2003 ISA – The Instrumentation, Systems, and Automation Society

All rights reserved.

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10 9 8 7 6 5 4 3 2

ISBN 1-55617-800-X

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Library of Congress Cataloging-in-Publication Data
Polka, David.
> Motors & drives / by David Polka.
> p. cm.
> Includes bibliographical references and index.
> ISBN 1-55617-800-X
> 1. Electric motors. 2. Electric driving. I. Title:Motors and
> drives. II. Title.
> TK2514 .P65 2002
> 621.46--dc21
> 2002012843
Dedication
This book is dedicated to my wife, Candy, and my daughter, Korey. Their
support, understanding and encouragement has been monumental in the
creation of this literary work. (Maybe I’ll get more projects done around the
house, now that my work is complete.)

I also dedicate this book to my parents, Chet and Carol, who taught me to stick
to my goals, and that you can’t put a price-tag on the value of education.
Teachers are essential to the creation of a welltrained and efficient functioning
society.
About the Author
Dave Polka has devoted his professional career to training and education, in
the areas of Electronics and Motor Speed Control. He graduated from the
University of Wisconsin – Stout, Menomonie, WI, with a Bachelor of Science
Degree in Industrial Education, and an emphasis in Electronics and Controls.

His first position was with Homestead High School, Mequon, WI, where he spent
eight years as an Industrial Education teacher. His programs included: Basic
Electricity and Electronics, Advanced Electronics and Instrumentation, and
Broadcast Radio.

He held several positions at Allen-Bradley’s Drives Division, Mequon, WI. He

spent three years as a Technical Writer of operation and maintenance manuals,
and seven years as Instructor and Supervisor of Drives Training, encompassing
sales, service and customer training.

Mr. Polka has published several trade journal and website articles, dealing with
topics such as: “What is a Drive?” “How to Maintain a VFD” and “Energy
Savings with VFDs in Paint Spray Booths.”

He currently holds the Training Center Manager position for ABB Inc, Drives &
Power Electronics, in New Berlin, WI. For the past eight years, he has
conducted distributor and customer classes on drive - applications,
programming and operation, for ABB University.

Acknowledgments
There are many people that had a hand in the success of this project. It could
not have been created by one person – working in a vacuum. I would like to
thank the following people for their assistance in making this book, what it is.

I would be remiss in mentioning the people that inspired me throughout the

years – to do my best, research until I find answers, and persist in the pursuit of
excellence. I began my knowledge base, through the direction and guidance
given by those at Allen-Bradley, now Rockwell Automation. I especially
appreciated the assistance by the late Jim Bonham. His insight into the world of
AC and DC drives gave me a foundation from which to grow. I also thank
Howard Murphy, Dave Caruana, Scott Patterson, Clarence Phipps, Jerry
Muehlbauer and Glenn Reinders, for their assistance throughout my formative
years.
I also want to thank Ken Graber of Zigman Joseph Stephenson, for his guidance
and encouraging me to accept the challenge of writing technical articles, and
ultimately, the writing of this book. Ken has injected a shot of “reality” into a
rather hectic writing schedule, both professionally and personally.

I want to thank my professional colleagues at ABB Inc. First and foremost,

Chuck Clark, for his approval of the use of various written works, as well as
photos and graphics. I also thank Roy Coleman and Joe Maloni for allowing me
time to pursue my publishing goals. I also acknowledge the following
individuals for their proofreading and technical suggestions: Becky Nethery,
Mark Kenyon, John Sutschek, Randy Stevens, Dennis Miller, Michael Tews, Jim
Nash, Tim Gladd, and Stuart Koym. I thank Jamieson Greig, for his insight into
legal aspects of literature.

Mike Olson, has been my mentor, and very instrumental in the completion of
this literary work. I appreciated his encouragement, proofreading and technical
expertise. An accomplished author himself, Mike has always made time for my
last minute questions and offered constructive criticism – that ultimately made
my written documents more understandable and technically accurate.

I also thank Bill Wagner for his scanning, creation and digital photography
techniques, as well as Randy Stevens, for his photo art rework and graphics
assistance. I thank those affiliated with ABB, directly or indirectly, including:
Chuck Cowie, Todd Vigorito and Walt Dembiczak for their
insight, suggestions and comments on previously written material.

The people at ISA have been most helpful in guiding me through the maze of
writing requirements. I especially thank Matt Lamoreaux for his
encouragement, and Shandra Botts for her schedule keeping. I also thank Joice
Blackson, for her assistance in the early stages of this project.
Introduction
To some, motor speed control is somewhat of a mystical science, a science that
causes motors and machines to sometimes operate in unexpected ways. Over
30 years ago, AC drives were considered “new technology.” If a company
wanted to have reliable production, it should stick with known, proven
technology – that of DC drives and motors. In many cases, the cost of
transferring manufacturing machinery to AC technology, would not warrant the
lengthy paybacks. It seemed that AC technology had a long way to go, to
improve in reliability and reduced cost. In some technician’s minds, you would
need to have a new, back-up AC drive, because the first one would probably
fail upon start-up.

As time marched on, low horsepower AC technology improved to the point

where total installed costs, including the motor, were equal to – or even less
expensive than the DC alternative. The size of the AC drive was equal to or
smaller that its DC counterpart. Improvements in power electronics increased
the reliability of AC drives, to the point where one would almost never hear of a
drive failure upon start-up.

This book is intended to de-mystify drive and motor technology, used in today’s
modern manufacturing processes. The text has roots in the practical side of
drive and motor use, with the “design engineering” side of technology,
presented in commonly used terms. An attempt is made to help the reader
“start from scratch,” gathering and reviewing a collection of basic information –
from basic electrical principles to DC and AC motor principles of operation. The
initial cost of a motor only represents about 3% of its total lifetime expense,
with operating costs representing the other 97%. Therefore, energy savings
with VFDs (variable frequency drives) is a topic that faces many consumers in
this day of rising energy costs.

From the basics, the reader is lead on a historical path – reviewing DC and AC
drives that are 10 years old or more. The focus of this section however, points
to the new and improved technology, in both types of drives.
From that point, the reader is lead into feedback methods and devices, and
into closed loop control of drive systems. The concepts reviewed, are the
basics of modern industrial and commercial HVAC systems.

An overall attempt is made to start with the basics, and move into the more
complex concepts of drive operation and design. The book also compares the
two technologies, AC and DC, and provides questions and issues to review
when making any drive technology decision. The book ends with general
principles of drive troubleshooting, and ideas on how to conduct routine drive
maintenance.

Summary sections and “Test your Knowledge” questions are provided at the
end of each chapter, to assist in confirming important points. In addition, the
Appendices are offered as a reference section, providing terms and definitions,
as well as formulas, conversions and enclosure information.

Many types of drives are on the market today – ranging from the size of a
person’s fist – to 14 bay cabinets, with the electronics to power thousands of
motor horsepower. Open loop (V/Hz) AC drives are the most common drive in
use today, with up to 70% use, according to some surveys. Behind the
standard open loop drive, stands several other types of drive products: brush
DC servo drives, DC drives, SCR DC drives, stepper drives / motors, AC servo
drives, and brushless DC servo drives. Though in smaller percentage of use,
encoderless flux vector, closed loop vector, and direct torque control type
drives are gaining in popularity.

It is hoped that this book can be used as a resource for those that design, apply
or maintain AC or DC motor speed controls. It is meant to be an overall “book
of knowledge” on a student’s, technician’s or engineer’s bookshelf.
Contents
About the
Author....................................................................................... ix

Acknowledgments .............................................................................
........ xi

Introduction.......................................................................................
....... xiii

Chapter 1: What is a
Drive? ........................................................................1

Drive Principles of Operation...............................................................5

Types of Drives, Features and Principles..............................................7

Chapter Review .................................................................................14

Check Your Knowledge .....................................................................14

Chapter 2: Review of Basic

Principles ....................................................15
Introduction.......................................................................................15

Electrical Principles ............................................................................15

Electrical/Electronic Devices ..............................................................29

Mechanical Principles ........................................................................41

Mechanical Devices............................................................................58

Chapter Review .................................................................................65

Check Your Knowledge .....................................................................67

Chapter 3: AC and DC
Motors..................................................................69

Introduction.......................................................................................69

DC Motors: General Principles of Operation......................................69

AC Motors: General Principles of Operation......................................90

Servomotors: General Principles of Operation.................................122

Chapter Review ...............................................................................127

Check Your Knowledge ...................................................................129

Chapter 4: AC and DC
Drives .................................................................131

Introduction.....................................................................................131

DC Drives .........................................................................................131

AC Drives .........................................................................................156

Chapter Review ...............................................................................201

Check Your Knowledge ...................................................................203

Chapter 5: Drive Control and Feedback Devices ................................
205

Open-Loop Control.......................................................................... 205

Closed-Loop Control........................................................................ 206

Drive Control Methods: DC ............................................................. 216

Drive Control Methods: AC ............................................................. 219

Sensors and Controls ....................................................................... 226

Chapter Review ............................................................................... 228

Check Your Knowledge ................................................................... 229

Chapter 6: Drive System Control Methods..........................................

231

Introduction..................................................................................... 231

Coordinated Drive Systems.............................................................. 231

DC Systems ...................................................................................... 246

AC Systems ...................................................................................... 251

AC versus DC Drive Systems ........................................................... 257

Chapter Review ............................................................................... 261

Check Your Knowledge ................................................................... 261

Chapter 7: Maintenance and Troubleshooting of Drive Systems..... 263

Routine Drive Maintenance ............................................................ 263

General Troubleshooting ................................................................. 269

Chapter Review ............................................................................... 270

Check Your Knowledge ................................................................... 271

Chapter 8: Final Review & Closing Remarks.......................................
273

What is a Drive? Why Drives are Applied ....................................... 273

Review of Basic Principles ............................................................... 273

Motors.............................................................................................. 275

Drives............................................................................................... 276

Drive Control and Feedback Devices ............................................... 278

Drive Systems .................................................................................. 279

Maintenance and Troubleshooting of Drive Systems ...................... 280

Closing Remarks .............................................................................. 280

Chapter 9: Check Your

Knowledge.......................................................283

Appendix A: Check Your Knowledge - Answers ...............................

287

Appendix B: Formulas and Conversions..............................................

301

Appendix C: Drive Enclosure Types .....................................................

311

Appendix D: Terms and Definitions.....................................................

315

Bibliography......................................................................................
........ 355

Index ................................................................................................
.......... 359