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The motor calculations presented here apply to changing conditions of a blower motor when pulley
adjustments are made. However, these calculations are useful wherever electric motors are used.
These simple calculations can be used to solve motor installation and troubleshooting problems in
a variety of applications. These motor formulas and related information are also basic to
understanding energy consumption, power consumption by motor-driven devices, and the motor
side of performing energy audits.
Fundamental to these useful calculations is some understanding of the information contained on a
motor data plate.
Shown is a belt drive fan and blower motor. (Photo courtesy of the HVACR Motors group of
Emerson.)
Voltage
The voltage listed on the data plate is the design voltage the motor was made for. The motor may be
operated at any voltage within 10 percent of the design voltage.
Full Load Amps (FLA)
This amperage is the current the motor will draw when the motor is loaded up to its rated
horsepower. The motor will draw less than the listed FLA if the motor is operating at less than the
rated horsepower. The motor will draw more than the rated FLA when it attempts to operate at
more than the rated horsepower. Measuring the actual motor amperage and comparing it to the
FLA is a good way to quickly tell if a motor is overloaded.
Locked Rotor Amps (LRA)
This amperage is the current the motor will draw when the motor is started and when the motor is
attempting to start and run but is unable to do so for some reason such as mechanically stuck
bearings. A rotor is said to be locked anytime the rotor is not rotating. This is normal on a motor
that is off and ready to start. If a motor has bad bearings and cannot start, the proper terminology
for that condition is to say the motor has stuck or frozen bearings. It would not be correct to say the
motor has a locked rotor. All motors when off have locked rotors. The LRA rating of a motor is the
most amperage the motor can draw under any condition.
Percent Efficiency
The rated percent efficiency for the motor is listed on most motors but not all. Motors that fail to
state their efficiency probably have poor efficiency ratings. If the efficiency is not given, it can still
be determined using basic math. Generally higher efficiency motors are those that use more metal
in their construction and the metal is laminated and insulated between laminations to reduce eddy
currents, which create heat. Heat in a motor is lost efficiency. The efficiency rating may be given as
a percent such as 86 percent, or the same percentage may be listed as a decimal fraction like 0.86.
When using the percent efficiency in a math formula, it must be used as a decimal fraction.
Power Factor
The power factor is also given as a decimal fraction and may be any number less than one. Common
power factor (PF) ratings range from 0.70 to 0.98. The higher power factor is always more desirable.
The power factor is a number that tells to what extent the motor voltage and current are out of
phase from one another. Unlike pure resistive circuits like electric heaters and incandescent lights,
motors operate with strong magnetic fields present. The magnetic fields add a new element of
magnetic resistance to the motor circuit, which throws the voltage and current out of phase with
one another. When the voltage and current are not in phase, Ohm's law will not work unless the
power factor is used to correct for this phase difference. The power factor listed on a motor is very
useful to the technician when making motor horsepower and current calculations.
Service Factor
The service factor of a motor is a number that indicates how much more work a given motor can do
beyond the rated horsepower. This is a safety factor and is not to be considered a part of the motor's
normal useful horsepower. A motor may have no service factor whatsoever and thus has no safety
factor in the event the motor becomes overloaded. A common service factor on motors is a SF of
1.15. This number multiplied times the rated horsepower gives the actual horsepower the motor
could operate at in an emergency. For example; a 10 hp motor with a SF of 1.15 could actually
provide service for a short time up to 11.5 hp. A motor with a high service factor is used in
applications where the load may vary and may occasionally result in an unexpected overload in
horsepower. Air conditioning systems often use motors with a SF rating of 1.15.
The service factor can also be multiplied times the FLA of the motor to give the absolute highest
operating amperage the motor should be allowed to operate with. This use of the service factor is
not recommended, as it is not completely reliable since it assumes the voltage the motor is getting
is exactly correct. This is also a poor service practice because it encourages technicians to allow
loading motors up into the safety zone the service factor provides.
Notice that the voltage times the amperage in the top of the formula not only gives the wattage, but
the wattage is then multiplied times the percent efficiency and the power factor. The wattage
gotten by multiplying the motor voltage times the motor amperage assumes that the motor is 100
percent efficient. Nothing is 100 percent efficient and motors are no exception. The efficiency of
this motor is 86 percent, so the wattage is reduced to 86 percent of the calculated wattage by
multiplying by 0.86. The reduced efficiency was lost in the form of heat and never produced the
work in the form of rotational force which motors are made to do.
Obviously, the higher the efficiency the better and also the higher the initial cost to purchase.
However, the energy savings from the higher efficiency may offset the higher initial cost.
Remember, the power the utility bill reflects is all the power the motor uses, not just what the
motor converted to useful rotational work but even the power lost to heat. A higher efficiency
motor wastes less power to heat loss and may run less to get the same amount of work
accomplished than a lower efficiency motor. Generally, it pays to purchase higher efficiency motors
unless the motor is a small one. Small motors usually do not consume enough power to pay back
the cost of the higher efficiency.
After correcting the motor wattage for the efficiency of the motor, the result is then corrected for
the power factor of the motor by multiplying by the power factor rating listed on the motor data
plate. The power factor was defined earlier as the degree that the voltage and current are out of
phase with one another. A power factor less than one indicates that the two are not perfectly in
phase, so the actual power the motor is working at is not what it could be if the voltage and
amperage were perfectly in phase. Knowing and using the power factor and efficiency in motor
calculations is vitally important if solid, useful numbers are to be attained.
This is the three-phase formula for determining motor horsepower including the addition of the
1.73 in its proper place. The 1.73 is the square root of the number 3 for the three phases.
In order to determine missing values of efficiency and/or power factor, the formula is the same as
for single-phase except the 1.73 is included in the calculation.
Three-phase (Percent Efficiency/PF) = hp x 746/E x I x 1.73
Use this formula just like the single-phase version.
Norm Christopherson is a senior training specialist with York International UPG in Norman, Okla.
He is the author of a new book by PAL Publications titled HVAC Technician's Certification Exam
Guide. He can be reached at norman.christopherson@york.com.
Publication date: 11/01/2004