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ACS 2000 4kV

Constant Torque
Applications

Abstract
This application guide specifies the torque vs speed limitations that need to be considered when
applying Normal Duty and Heavy Duty rated drives.

No. of p.
Prep. R Hoadley 30 January 2012 ACS 2000 4kV
Appr. M Basler Constant Torque Applications 18
Resp.
dept. MV Drives
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Contents

1 ..... Introduction ....................................................................................................................................... 3

1.1 Purpose of this document ........................................................................................................ 3
1.2 Background.............................................................................................................................. 3
1.3 Definitions ................................................................................................................................ 3
2 ..... Application ........................................................................................................................................ 4
2.1 Normal Duty, Encoderless, Motoring and Regen...................................................................... 5
2.2 Normal Duty, Encoder, Motoring .............................................................................................. 7
2.3 Normal Duty, Encoder, Regen ................................................................................................. 9
2.4 Heavy Duty, Encoderless, Motoring and Regen ..................................................................... 11
2.5 Heavy Duty, Encoder, Motoring ............................................................................................. 13
2.6 Heavy Duty, Encoder, Regen ................................................................................................. 15
3 ..... Drive Ratings .................................................................................................................................. 17
4 ..... Conclusion ...................................................................................................................................... 17
5 ..... Revisions ........................................................................................................................................ 18

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1 Introduction

1.1 Purpose of this document

There are limitations that need to be considered in Constant Torque Applications when using this
drive. This document provides guidelines to help select the proper drive rating based on speed, torque
and overload requirements.

1.2 Background
Use these application curves when applying the ACS 2000 4kV to variable and constant torque
applications - such as fans, pumps, reciprocating pumps, gear pumps, mixers, extruders, conveyors,
test stands, screw type air compressors, positive displacement pumps, vacuum pumps, and punch
presses.

1.3 Definitions
The following terms are defined:
<10 sec – The current vs speed area (red area) where the drive may operate for a maximum of 10
seconds. The operating point needs to move to another area after that time.
1min / 10min – The current vs speed area (yellow area) where the drive may operate for a maximum
of 1 minute out of every 10 minutes. This is the overload region.
(hh,aa) – The rectangular coordinates shown on the following graphs provide the locations of the
points of interest. The format is (Hertz, Amps rms). The frequency is in Hz output from the drive. The
current is in Amps rms output from the drive.
Cold Start - Starting the drive and motor out of a cold condition. After turning off the drive the cooling
fans continue to run for 7 minutes; after that period the drive is fully cooled down and has reached a
cold condition.
Continuous Operation – the current vs speed area (green area) where the drive may operate
continuously with no time limitations.
Encoder – A motor that has an encoder for speed feedback to the drive.
Encoderless – A motor that does not have an encoder for speed feedback to the drive.
Variable Torque (Also known as Square Torque) – applications that require reduced torque when
driven at speeds less than the base speed of the motor. Many variable torque loads see a current
decrease with the square of the speed. This is characteristic of centrifugal pumps, and certain types of
fans and blowers. Typically, as the speed decreases, the torque decreases with the square of the
speed and the horsepower decreases with the cube of the speed.
Constant Torque – applications where the torque loading is not a function of speed. Typical
applications are: conveyors, positive displacement pumps and hoists. As the speed changes, the load
torque remains constant and the horsepower changes linearly with speed. Constant torque loads
cause motors to draw relatively high current at low speeds when compared to variable torque
applications. This is why the same size drive may have a lower HP rating for Constant Torque
applications.

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Motoring Operations – also known as 2 Quadrant Operating mode where the Torque and Rotation are
in the same direction. One quadrant is forward, the second is reverse where in each case energy is
flowing from the network and into the motor and converted to work.
Regenerative Operation (Regen) – also known as 4 Quadrant Operating mode where Torque and
Rotation are in opposite directions, both forward and reverse where in each case energy is flowing
from the motor (generator) into the network producing braking torque in the motor.
HD - Heavy Duty, where the maximum torque on the system will not exceed 150% of rated for more
than 1 minute out of every 10 minute cycle.
ND - Normal Duty, where the maximum torque on the system will not exceed 110% of rated for more
than 1 minute out of every 10 minute cycle.

2 Application
To use this application guide, the following information about the process is required:
torque (current) vs speed curve
It is also helpful to have the following information about the process:
speed vs time curve

Drive dimensioning note: The difference between control performance of encoderless and encoder
operation is primarily based on conservative considerations. Performance of encoderless operation
can be improved if equivalent motor circuit parameters are available.

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2.1 Normal Duty, Encoderless, Motoring and Regen
ND Encoderless operation needs to be limited within the red area due to voltage or current instabilities
that could otherwise result in the drive tripping. Accelerating through that region is acceptable as long
as the amount of time spent within that area is kept below 10 seconds.
As you can see, this allows the drive to operate variable torque loads without an encoder
continuously. However, if a constant torque load is being driven, its torque requirements need to be
limited either in magnitude vs speed, or in time vs speed. If the torque requirements of the load
exceed these curves, an encoder will need to be mounted to the motor or a Heavy Duty rated drive
will be required. Operation within the yellow area is allowed as long as the amount of time spent there
is kept within that time limit.

Frame 1
A rms
160
(20, 148.5)

140 1 min / 10 min

(20, 135.0)
120

100
< 10 sec
80
(0, 67.5) Continuous Operation
60

40 (15, 40.5)
(0, 40.5)

20

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Freq, Hz

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Frame 2
A rms
320
(20, 295.9)

280 1 min / 10 min

(20, 269.0)
240

200
< 10 sec
160
(0, 134.5) Continuous Operation
120

80 (15, 80.7)
(0, 80.7)

40

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Freq, Hz

Frame 3
A rms
480
(20, 444.4)

420 1 min / 10 min

(20, 404.0)
360

300
< 10 sec
240

(0, 202.0) Continuous Operation

180

120
(0, 121.2) (15, 121.2)

60

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Freq, Hz

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2.2 Normal Duty, Encoder, Motoring
ND Encoder, motoring operation needs to be limited within the red area due to thermal limitations of
the IGBT chips that could otherwise result. Accelerating through that region is acceptable as long as
the amount of time spent within that area is kept below 10 seconds and it is a cold start. Operation
within the yellow area is allowed as long as the amount of time spent there is kept within that time
limit.

Frame 1
A rms
160
(0, 148.5) (10, 148.5)

140 < 10 sec 1 min / 10 min

(10, 135.0)
120

100

80

60 (0, 67.5) Continuous Operation

40

20

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Freq, Hz

Frame 2
A rms
320
(0, 295.9) (10, 295.9)

280 < 10 sec 1 min / 10 min

(10, 269.0)
240

200

160

120 Continuous Operation

(0, 121.1)

80

40

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Freq, Hz

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Frame 3
A rms
480
(0, 444.4) (10, 444.4)

420 < 10 sec 1 min / 10 min

(10, 404.0)
360

300

240

180 (0, 202.0) Continuous Operation

120

60

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Freq, Hz

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2.3 Normal Duty, Encoder, Regen
ND Encoder, regen operation needs to be limited within the red area due to thermal limitations of the
IGBT chips that could otherwise result. Accelerating through that region is acceptable as long as the
amount of time spent within that area is kept below 10 seconds and it is a cold start. Please note that
no overload is allowed.

Frame 1
A rms
160

140 (0, 135.0) (10, 135.0)

< 10 sec 1 min / 10 min

120 (10, 121.5)

100

80
(0, 67.5) Continuous Operation
60

40

20

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Freq, Hz

Frame 2
A rms
320

280 (0, 269.0) (20, 269.0)

< 10 sec 1 min / 10 min

240 (20, 242.1)

200

160
Continuous Operation
120 (0, 121.1)

80

40

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Freq, Hz

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Frame 3
A rms
480

420 (0, 404.0) (10, 404.0)

< 10 sec 1 min / 10 min

360 (10, 363.6)

300

240
(0, 202.0) Continuous Operation
180

120

60

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Freq, Hz

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2.4 Heavy Duty, Encoderless, Motoring and Regen
HD Encoderless operation needs to be limited within the red area due to voltage and current
instabilities that could otherwise result in a trip. Accelerating through that region is acceptable as long
as the amount of time spent within that area is kept below 10 seconds. Operation within the yellow
area is allowed as long as the amount of time spent there is kept within that time limit.

Frame 1
Arms
160
(20, 148.5)

140 1 min / 10 min

(20, 135.0)

120

100
(18.1, 99.0)
< 10 sec
80
(0, 67.5) Continuous Operation
60

40 (0, 40.5) (15, 40.5)

20

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Freq, Hz

Frame 2
Arms
320
(20, 295.9)

280 1 min / 10 min

(20, 269.0)

240

200
(18.1, 197.3)
< 10 sec
160
(0, 134.5) Continuous Operation
120

80 (0, 80.7) (15, 80.7)

40

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Freq, Hz

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Frame 3
Arms
480
(20, 444.4)

420 1 min / 10 min

(20, 404.0)

360

300
(18.1, 296.3)
< 10 sec
240
(0, 202) Continuous Operation
180

120 (0, 121.2) (15, 121.2)

60

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Freq, Hz

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2.5 Heavy Duty, Encoder, Motoring
HD Encoder, motoring operation needs to be limited within the red area due to thermal limitations of
the IGBT chips that could otherwise result. Accelerating through that region is acceptable as long as
the amount of time spent within that area is kept below 10 seconds and it is a cold start. Operation
within the yellow area is allowed as long as the amount of time spent there is kept within that time
limit.

Frame 1
Arms
160
(0, 148.5) (10, 148.5)

140 < 10 sec 1 min / 10 min

(10, 135.0)
120

100
(4.7, 99.0)

80
(0, 67.5) Continuous Operation
60

40

20

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Freq, Hz

Frame 2
Arms
320
(0, 295.9) (20, 295.9)

280 < 10 sec 1 min / 10 min

(20, 269.0)
240

200
(10.3, 197.3)

160
Continuous Operation
120 (0, 121.1)

80

40

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Freq, Hz

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Frame 3
Arms
480
(0, 444.4) (10, 444.4)

420 < 10 sec 1 min / 10 min

(10, 404.0)
360

300
(4.7, 296.3)

240
(0, 202.0) Continuous Operation
180

120

60

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Freq, Hz

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2.6 Heavy Duty, Encoder, Regen
HD Encoder, regen operation needs to be limited within the red area due to thermal limitations of the
IGBT chips that could otherwise result. Accelerating through that region is acceptable as long as the
amount of time spent within that area is kept below 10 seconds and is a cold start. Operation within
the yellow area is allowed as long as the amount of time spent there is kept within that time limit.

Frame 1
Arms
160

140 (0, 135.0) (10, 135.0)

< 10 sec 1 min / 10 min

120 (10, 121.5)

100
(5.8, 99.0)

80
(0, 67.5) Continuous Operation
60

40

20

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Freq, Hz

Frame 2
Arms
320

280 (0, 269.0) (20, 269.0)

< 10 sec 1 min / 10 min

240 (20, 242.1)

200
(12.6, 197.3)

160
Continuous Operation
120 (0, 121.1)

80

40

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Freq, Hz

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Frame 3
Arms
480

420 (0, 404.0) (10, 404.0)

< 10 sec 1 min / 10 min

360 (10, 363.6)

300
(5.8, 296.3)

240
(0, 202.0) Continuous Operation
180

120

60

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Freq, Hz

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3 Drive Ratings
That following table provides the full load ratings for the frames and sub-frames for the ACS2000 4kV
drive family.
Frame Type ND HP ND Rated Max 110% HD HP HD Rated Max 150%
Size Code Rating Current Current Rating Current Current
0C 300 40 44 220 29 44
0D 350 47 52 257 34 52
0E 400 54 59 293 40 59
0F 450 61 67 330 45 67
Frame 1

0H 500 67 74 367 49 74
0L 600 81 89 440 59 89
0Q 700 94 103 513 69 103
0R 800 108 119 586 79 119
0T 900 121 133 660 89 133
0V 1000 135 149 733 99 149
0Z 1250 168 185 916 123 185
Frame 2

1C 1500 202 222 1100 148 222

1F 1750 236 260 1283 173 260
1H 2000 269 296 1466 197 296
1J 2250 303 333 1649 222 333
Frame 3

1N 2500 337 371 1833 247 371

2A 2750 370 407 2016 271 407
2B 3000 404 444 2199 296 444

4 Conclusion
As noted above, the time spent within the red areas needs to be adhered to. Likewise, the amount of
time allowed in the yellow overload regions should not be exceeded.

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5 Revisions
Rev. Page (P) Description Date/Init.
ind. Chapt.(C)
V1 Initial version 01/01/12 rh
V2 Updated diagrams 02/22/12 rh
V3 Updated text, diagrams 02/29/12 rh
V4 Updated definitions 05/10/12 rh
V5 Updated diagrams, showing current vs frequency and by Frame 08/26/14 rh
number

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