Motor_Basics

Motor Basics AGSM 325 Motors vs Engines • Motors convert electrical energy to mechanical energy. • Engines convert chemical energy to mechanical energy. www.PAControl.com 1 Motors • Advantages – – – – – – – – Low Initial Cost - $/Hp Simple & Efficient Operation Compact Size – cubic inches/Hp Long Life – 30,000 to 50,000 hours Low Noise No Exhaust Emissions Withstand high temporary overloads Automatic/Remote Start & Control • Disadvantages – Portability – Speed Control – No Demand Charge Magnetic Induction • Simple Electromagnet • Like Poles Repel • Opposite Poles Attract www.PAControl.com 2 Operating Principle Motor Parts • • • • • • Enclosure Stator Rotor Bearings Conduit Box Eye Bolt www.PAControl.com 3 Enclosure • Holds parts together • Helps with heat dissipation • In some cases, protects internal components from the environment. Stator (Windings) • “Stationary” part of the motor sometimes referred to as “the windings”. • Slotted cores made of thin sections of soft iron are wound with insulated copper wire to form one or more pairs of magnetic poles. www.PAControl.com 4 Rotor • “Rotating” part of the motor. • Magnetic field from the stator induces an opposing magnetic field onto the rotor causing the rotor to “push” away from the stator field. Wound Rotor Motors • Older motor designed to operate at “variable speed” • Advantages – Speed Control, High Starting Torque, Low Starting Current • Disadvantages – Expensive, High Maintenance, Low Efficiency www.PAControl.com 5 Bearings • Sleeve Bearings – – – – Standard on most motors Quiet Horizontal shafts only Oil lubricated • Ball (Roller) Bearings – Support shaft in any position – Grease lubricated – Many come sealed requiring no maintenance Other Parts • Conduit Box – Point of connection of electrical power to the motor’s stator windings. • Eye Bolt – Used to lift heavy motors with a hoist or crane to prevent motor damage. www.PAControl.com 6 Motor Speed • Synchronous Speed – Speed the motor’s magnetic field rotates. – Theoretical speed with not torque or friction. • Rated Speed – Speed the motor operates when fully loaded. – Actual speed at full load when supplied rated voltage. Synchronous Speed • Theoretical Speed • A well built motor may approach synchronous speed when it has no load. • Factors – Electrical Frequency (cycles/second) – # of poles in motor www.PAControl.com 7 Rated Speed • Speed the motor runs at when fully loaded and supplied rated nameplate voltage. Motor Slip • Percent difference between a motor’s synchronous speed and rated speed. • The rotor in an induction motor lags slightly behind the synchronous speed of the changing polarity of the magnetic field. – Low Slip Motors • “Stiff”….High Efficiency motors – High Slip Motors • Used for applications where load varies significantly…oil pump jacks. www.PAControl.com 8 Torque • Measure of force producing a rotation – Turning Effort – Measured in pound-feet (foot-pounds) Torque-Speed Curve • Amount of Torque produced by motors varies with Speed. • Torque Speed Curves – Starting Torque – Pull Up Torque – Breakdown Torque www.PAControl.com 9 Motor Power • Output Power – Horsepower – Amount of power motor can produce at shaft and not reduce life of motor. • Input Power – Kilowatts – Amount of power the motor consumes to produce the output power. Calculating Horsepower • Need Speed and Torque • Speed is easy – Tachometer • Torque is difficult – Dynamometer – Prony Brake www.PAControl.com 10 Watt’s Law • Input Power • Single Phase – Watts = Volts X Amps X p.f. • Three Phase – Watts = Avg Volts X Avg Amps X p.f. X 1.74 Example • Is a 1 Hp 1-phase motor driving a fan overloaded' – Voltage = 123 volts – Current = 9 amps – p.f. = 78% • Watts = Volts X Amps X p.f. Watts = 123 volts X 9 amps X 0.78 = 863.5 Watts 864 Watts / 746 Watts/Hp = 1.16 Hp • Is the motor overloaded' www.PAControl.com 11 Electrical = Input • We measured Input • Motors are rated as Output • Difference' – Efficiency • If the motor is 75% efficient, is it overloaded' • Eff = Output / Input • Output = Eff X Input 0.75 X 1.16 Hp = 0.87 Hp 1.16 Hp Input • The motor is NOT overloaded HP Output' Example #2 • Is this 10 Hp, 3-phase motor overloaded' – Voltages = 455, 458, and 461 volts – Currents = 14.1, 14.0 and 13.9 amps – P.f. = 82% • Watts = Voltsavg X Ampsavg X p.f. X 1.74 Watts = 458v X 14a X 0.82 X 1.74 = 9148.6 Watts 9148.6 Watts / 746 Watts/Hp = 12.26 Hp • Is the motor overloaded' www.PAControl.com 12 Example #2 • We measured Input • Motor is rated as Output • Difference' – Efficiency 12.26 Hp Input • If the motor is 90% efficient, is it overloaded' • Eff = Output / Input • Output = Eff X Input 0.90 X 12.26 Hp = 11.0 Hp • The motor IS overloaded! • How bad is the overload' Hp Output ' Motor Types CLASSIFICATION OF MOTORS AC MOTORS Polyphase Synchronous Universal Single-Phase Synchronous Induction Induction Hysteresis Reluctance Squirrel Cage Hysteresis Reluctance Wound Rotor Squirrel Cage Permanent Magnet Wound Rotor Wound Rotor Synchronous Design Design Design Design A B C D Repulsion Repulsion Start Split Phase Capacitor Run Capacitor Start Capacitor Start/Run www.PAControl.com 13 Synchronous vs Induction Motors • Synchronous Motors – Turn at exactly the same speed as the rotating magnetic field. – 3600 rpm, 1800 rpm, etc. • Induction Motors – Turn at less than synchronous speed under load. – 3450 rpm, 1740 rpm, etc. NEMA 3 Phase Motors • 3 Phase Induction Motors • NEMA TorqueSpeed Design Types – A,B,C,D,E www.PAControl.com 14 Design Type B • Today’s “Standard” 3Phase Motor • Good Starting Torque – In-rush amps 4-6 times full load amps – Good breakdowntorque – Medium Slip Design Type A • The “old” Standard • Higher starting torque than “B”. • Higher in-rush current (5-8 times full load amps) • Good breakdown torque www.PAControl.com 15 Design Type C • Common OEM equipment on reciprocating pumps, compressors and other “hard starting” loads. • High starting torque • Moderate starting current (5-8 times FLA) • Moderate breakdown torque Design Type D • Common on applications with significant loading changes as a machine operates. • Impact Loads – Punch Presses, Metal Shears, etc. – Pump Jacks www.PAControl.com 16 Design Type E • Newest NEMA Category • Newer ultra-high efficiency motors – Higher Starting Torque – Higher Starting Current (8-12 times Running) – Ultra Low Slip (Higher Rated Speed) Single Phase Induction Motors • Are not “self starting” – Require a starting mechanism. • The name generally describes its “starting mechanism”. – – – – – – – Split Phase Capacitor Run Capacitor Start Capacitor Start-Capacitor Run Shaded Pole Synchronous Universal www.PAControl.com 17 Split Phase Motor • Common small single phase motor – Good Starting Torque – Moderate Efficiency – Moderate Cost • Small conveyors, augers, pumps, and some compressors • 1/20th to ¾ Hp, available to 1.5 Hp Split Phase Motor • Starting winding in parallel with Running winding • Switch operates at 70-80% of full speed. • Centrifugal Switch – Sticks Open – Sticks Shut www.PAControl.com 18 Capacitor Run Motor (Permanent Split Capacitor or PSC) • Primarily a fan and blower motor. • Poor starting torque • Very low cost motor. Permanent Split Capacitor (PSC) • Capacitor in “Capacitor Winding” – Provides a “phase shift” for starting. – Optimizes running characteristics. • No centrifugal switch www.PAControl.com 19 Capacitor Start Motor • Larger single phase motors up to about 10 Hp. • A split phase motor with the addition of a capacitor in the starting winding. • Capacitor sized for high starting torque. Capacitor Start Motor • Very high starting torque. • Very high starting current. • Common on compressors and other hard starting equipment. www.PAControl.com 20 Capacitor Start-Capacitor Run • Both starting and running characteristics are optimized. – High starting torque – Low starting current – Highest cost • For hard starting loads like compressors and pumps. • Up to 10 Hp or higher is some situations. Capacitor Start-Run Motor • Larger single phase motors up to 10 Hp. • Good starting torque (less than cap start) with lower starting current. • Higher cost than cap start. www.PAControl.com 21 Synchronous Motor • Special design for “constant speed” at rated horsepower and below. • Used where maintaining speed is critical when the load changes. Universal Motor • Runs on AC or DC • Commutator and brushes • Generally found in portable power tools. • Lower Hp sizes www.PAControl.com 22 Universal Motor • Very high starting torque. • Higher torque on DC than AC (battery operated tools) • The higher the rpm, the lower the torque. www.PAControl.com 23