Review of How Motor Works

Motor converts Electrical Energy to Rotating Mechanical

Energy Coils placement in motor creates rotating, magnetic field in stator Rotating magnetic field cuts rotor bar and induces current in rotor Rotor current creates magnetic field on rotor Attraction of rotor to stator creates torque and, hence, horsepower

AC Motor Review
In an AC Motor, speed varies by:

Motor Speed (rpm) = 120 x Frequency - Slip

# of Poles

Since you can not change the number of poles in an AC motor, the frequency is changed to vary the speed.

Varying the Speed of an AC Motor

1800 (rpm)

1800 = 60 x 120 (rpm) 4

900 (rpm)

900 = 30 x 120 (rpm) 4

30 Hz

60 Hz

AC Motor Review
In an AC motor, Torque Varies by: E 2 T = K x ( ) x I Line F Where: K is a constant E is applied voltage F is input frequency I Line is motor current

AC Motor Review Torque/Current Relationship

What you really need to know...

Current is roughly proportional to load torque The higher the load torque the higher the current

AC Motor Review
Horsepower of an AC motor can be determined by:

HP = Torque x Speed 5252

Where:

Torque is in lb-ft Speed is in RPM 5252 is a constant

Motor nameplate Horsepower is achieved at Base RPM:

HP = Torque * Speed / 5252

Constant Torque Range Constant Horsepower Range

Torque 100%

Note that motor nameplate horsepower is only achieved at and above base speed, NOT BEFORE. Base Speed RPM

Operation Above Base Speed

HP

AC Motor Review IMPEDANCE

IMPEDANCE: Resistance of AC Current flowing through the windings of an AC Motor

NOTE: Impedance decreases as frequency decreases

Volts/Hertz Relationship

I = Current V = Voltage Z = Impedance

I=V Z

To reduce motor speed effectively: Maintain constant relationship between current & torque A constant relationship between voltage and frequency must be maintained

Volt/Hertz Relationship
460 V

230 V

The AC variable speed drive controls voltage & frequency simultaneously to maintain constant volts-per-hertz relationship keeping current flow constant.

30 Hz

60 Hz

AC Drive
Rectifier DC Bus Inverter AC Power Supply

Rectifier - Converts AC line voltage to Pulsating DC voltage

Inverter - Changes fixed DC to adjustable AC - Alters the Frequency of PWM waveform

Intermediate Circuit (DC BUS)

- Filters the pulsating DC to fixed DC voltage

Sine Weighted PWM

Bus Voltage Level

Sine Weighted PWM

PWM WAVEFORM
+ DC Bus 1 - DC Bus 3 Phase Current 10 Amps / Div. M2.00s Ch1 VLL @ Drive 500 Volts / Div.

1.18V

PWM waveform is a series of repetitive voltage pulses

Drive and Motor Compatibility

Voltage Wave @Drive Output

VLL @ Drive 500 Volts / Div.

Potentially Damaging Voltage Peaks

VLL @ Motor 500 Volts / Div.

Voltage Wave @ Motor Conduit Box

How to Specify -- NEMA Standards MG1-1993, Part 31.40.4.2

Maximum of 1600 Volt Peaks
Vpeak

Voltage

100% 90%

Steady-state voltage

dV V dt t
10% t Rise time

Time

Minimum Rise Time of .1 Microseconds

GV3000/SE
V/Hz Operation
Output Voltage 460 Ratio @ 460VAC = 7.67 V/Hz 230 115 Hz

15

30

60 Base Frequency

90 Output Frequency

At Base RPM or 60Hz, the Motor sees line input voltage

GV3000/SE
V/Hz Operation
Output Voltage 460 Ratio @ 460VAC = 7.67 V/Hz 230 115 Hz

15

30

60 Base Frequency

90 Output Frequency

At 25% of Base RPM or 15 Hz, Voltage & Frequency is 25%

VECTOR DRIVE
Magnetizing Current (8.5 Amps) 25.0 Amps Full Load

Torque - Producing Current (23.5 Amps)

Vector calculates Torque-Producing Current by knowing actual amps and magnetizing current.

GV3000/SE

Vector Control - Torque can be produced, as well as regulated even at 0 RPM

100% Torque Current

Motor Current is the VECTOR SUM of Magnetizing & Torque Current,

this is where the term VECTOR DRIVE is derived

Motor Current
90 Magnetizing Current

Torque Current 10%

90

Motor Current

Magnetizing Current

Motor Current is the Vector Sum of Torque & Magnetizing

GV3000/SE
Flux Vector Drive - simple diagram review
A Vector Drive always regulates current
LEM Current Sensors L1 L2 L3

Motor

E Micro P

Encoder feedback provides rotor speed & position information for calculations

GV3000/SE
Sensorless Vector Control - simple diagram review
SVC estimates rotor speed & position to the stator field
LEM Current Sensors L1 L2 L3 Micro P ( FVC + Speed Estimator )

Motor

A Speed Estimator calculates rotor speed & position to maintain 90 to the field

Sensorless Vector

Flux Vector

150% Overload Operation to 0 RPM

120:1 Speed Range Speed Regulation 40:1, 0.5% Steady State 20:1, 1.0% Dynamic Dynamic Response 100+ radian Speed Loop 1000 radian Torque Loop Tunable Speed PI gains

150% Overload Operation @ 0 RPM

1000:1 Speed Range Speed Regulation 100:1, 0.01% Steady State 100:1, 0.5% Dynamic Dynamic Response 100+ radian Speed Loop 1000 radian Torque Loop Tunable Speed & Torque PI gains

INVERTER DUTY MOTORS

NEMA Design B Motor w/ 3% Slip - Across the Line Start
BDT 200% LRT PUT

Operating Region on AC Drives

100%

FLT

Slip
Base RPM

AC Drives regulate Motor Speed based on designed slip

INVERTER DUTY MOTORS

Blowers may be added to motors to allow operation at low speed including 0 RPM with 100% Torque continuous

Some motor frames are sized so that just the surface area is suitable to dissipate motor heat w/o the need of a fan or blower

VXS Motors

GV3000/SE with Inverter & Vector Duty AC Motors

Based on Reliance XEX Motor Designs TENV, TEFC-XT and TEBC Enclosures Ideal for; Positive Displacement Pumps and Blowers Extruders and Mixers Steel and Converting Process lines Standard Features; Encoder Mounting Provisions

Motor Shaft Tapped for Stub @ ODE Accessory Face @ ODE

Motor Winding Thermostats, 1/Phase 10:1 to 1000:1 CT speed ranges w/o derating

RPM-AC Motors

GV3000/SE with Inverter & Vector Duty AC Motors

Laminated Steel, DC-style construction
DPFV, TENV, & TEBC enclosures

Ideal for;
Extruder applications Web processing & mill applications Retrofitting existing DC Drive & Motor systems

Standard Features;
High torque to inertia ratios Encoder Mounting Provisions Motor Winding Thermostats, 1/Phase Infinite CT speed range, 0 RPM continuous CHp Range of 2:1 on TENV & TEBC Frames Base Speeds from 650 RPM to 3600 RPM

Speed Range

Speed Range - Designed operating range of an inverter duty motor Example 1800 rpm motor 10:1 Speed Range = 180 -1800 (rpm)

CONSTANT TORQUE REGION

Speed / Torque Curve of an AC Drive & Inverter Duty Motor
100

Torque
90

% T O R Q U E

80 70 60 50 40 30 20 10 0 0 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90

Torque

Acceptable Region for Continuous Operation

HZ Inverter Duty Motors operate at 1/4th Base RPM

CONSTANT HP REGION
Speed / Torque Curve of an AC Drive & Inverter Duty Motor
100

Torque
90

% T O R Q U E

80 70 60 50 40 30 20 10 0 0 6 12 18 24 30 36 42 48 54

Torque

Torque above base RPM = 100% % Base RPM

60

66

72

78

84

90

HZ CHp Operation above Base RPM is typically limited to 150%

CONSTANT TORQUE REGION

Speed / Torque Curve of a Vector Drive & Vector Duty Motor
100

Torque
90

% T O R Q U E

80 70 60 50 40 30 20 10 0 0 6 12 18 24 30 36 42 48 54

Torque

Acceptable Region for Continuous Operation

60

66

72

78

84

90

HZ Vector Duty Motors operate at 0 RPM w/ 100% Torque Cont.

CONSTANT HP REGION
Speed / Torque Curve of a Vector Drive & Vector Duty Motor
100 90

% 80 T 70 O 60 R 50 Q 40 U 30 E 20
10 0 0 6 12 18 24

Special motor & drive designs can allow operation up to 8 * Base RPM

Torque Torque Vector Duty Motors may have CHP Ranges of 2 * Base Speed or more depending on their design
30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120

HZ Some Vector Duty Motors can provide CHp ( 2 * Base RPM )

Drive Terminology

V/Hz DC Boost Accel / Decel Frequency Voltage HP Speed Skip & Bandwith Braking DB Regen Injection Coast Ramp

Restart Preset Jog Current Limit Analog / Digital Power Factor Harmonics Ride - Thru Speed Range Speed Regulation Frequency Regulation Cogging Efficiency

Accel/Decel

Acceleration Rate - Deceleration Rate

Rate of change of motor speed.

100 %

Frequency
30 sec

Example: 0 Speed - 1750 rpm 30 seconds

TIME

Full Voltage Bypass

Drive Branch Fusing Bypass Disconnect Switch GV3000/SE Input Disconnect Switch Bypass Option M

Speed Regulation
How Much Will the Speed Change

Between No Load and Full Load?

Expressed as a Percentage

Speed Regulation

DC Voltage Boost

Voltage Boost
Voltage Boost over prolonged operating periods may result in overheating of the motors insulation system and result in premature failure.

CAUTION: Motor Insulation Life is decreased by 50% for every 10C above the insulations temperature capacity
Unable to perform like DC, the industry looks to Vector Control

Critical Frequency
An Output Frequency of a Controller that
Produces a Load Speed at Which Severe

Vibration Occurs.
A Frequency at which Continuous Operation

is Undesirable

Skip Bandwith
60 50

40
Command Freq. Output Freq Skip Band Skip Freq

30

20

10

0 0 1 2 3 4 5 6 7 8 9 10

AC Drive Inputs
Analog Inputs:
0-10 VDC 10 VDC 4-20 mA

Digital Inputs:
Start Stop Reset Forward/Reverse Run/Jog Preset Speeds

High Bus Avoidance ( SVC & FVC )

GV3000/SE

For Trip Free Deceleration if low to medium inertia loads

SPEED

TIME Trip Free Deceleration when enabled

Snubber/Dynamic Braking
Rectifier DC Bus Inverter AC Power Supply

Snubber/Dynamic Braking - Addition of Snubber Resitor Kit - Dissipates excess energy to regulate braking
Braking Resistor 7th IGBT

- Regulator monitors DC bus voltage

- Signal sent to 7th IGBT

- Handles short term regenerative loads - Less expensive than AC line regeneratiion braking

AC Regenerative Braking
AC Power Supply

AC Line Regeneration Module

Drive 1

Drive 2

Drive 2

Severe Regenerative Braking - Addition of AC Line Regeneration Module - Monitors DC bus voltage - Sends Excess voltage back to AC line - Handles long term regenerative loads - Run Multiple Drives off 1 Module

- Drives powered through DC bus instead of through the Rectifier bridge - Share regenerative energy between motoring and regenerating drives - Send energy back to AC Line instead of dissipating as heat

Auto - Restart
How will the drive react after being shut down by a fault condition? Will the drive resume Running after the Fault condition is Cleared? (Sometime restricted to certain Faults)

Preset Speeds

A Pre-Programmed Command Frequency

That can be activated via Mode

Select or Input Device

Current Limit

The ability of a drive to react to the increased current caused by momentarily increasing the load on the motor (Shock Loading) without tripping the drive on Overcurrent.

Power Loss Ride-Through

The Ability of a Controller to sustain itself through a loss of Input Line Voltage for a specific period of time.

Operating Range For Variable Frequency AC Drives