ADDlication Notes

As discussed previously, one should have a basic knowledge of how

motors and drive control systems interact in order to apply drives prop-
erly. An understanding of the relationships between torque, horsepower,
acceleration, and braking characteristics of an application is also
required. In this chapter we will discuss how to assemble a drive for a
new application. You might be the buyer, or the seller, but both must
take a systematic approach to picking the proper equipment.
One cannot ask too many questions. Even a seemingly insignificant
bit of information may tip one off to potential pitfalls to be avoided.
Asking questions also gives the customer a sense that you are interested
in his project, and it gives him an opportunity to explain what the
machine has to accomplish. If the customer understands his application,
he can ask the proper questions of his supplier to be assured the proper
drive is being recommended. Developing a close working relationship
with a key person is very important to a successful installation.

DEFINE MACHINE LOADS

Loads will generally fall into one of three categories:
Constant Torque. The load is essentially the same at all speeds.
A 10-ton load on a conveyor requires about the same torque at 5 feet
per minute as it does at 50 feet per minute. The horsepower demand
increases with speed.

117
I18 Variable Speed Drive Fundamentals

Constant Horsepower. The load decreases with increasing speed.

This application usually applies to processes that are changing diameter,
such lathes, winders, unwinders, etc. With a large diameter, maximum
torque and slow speeds are required. As the diameter decreases, torque
demand decreases, but speed increases to provide constant surface speed.
Variable Torque. The load increases with speed. This is usually
associated with centrifugal fan and pump loads. These applications have
the greatest opportunities for energy savings, as the power varies as the
cube of the speed. At this writing, many utility companies are offering
subsidies to encourage the use of variable speed drives on these applica-
tions for energy conservation.

PEAK LOAD
Peak loads are different with various machines. In one case, break-
away torque requirement is very high, as with a sticky conveyor. A high
inertia load that requires fast acceleration will likely to have maximum
demand during acceleration. Other applications will have maximum
demands in the running mode when sudden overloads may appear period-
ically. It is important to identify the worst-case loading. (See Chapter 14.)

AC OR DC DRIVE?
The choice between AC and DC drives may not be clear at first,
although there will usually be a stated preference. Trade-offs must be
considered between performance and cost. (See Figure 10-1.)

DEFINE THE MACHINE

We need to define just what the machine does, how it does it. Any
interrelationships that are coincidental with the operating cycle must be
defined.

Torque
What is the maximum torque required at the input shaft? This can
be determined as covered in the “Torque” discussion (Chapter 9), or as
provided by the builder of the machine. Are there special high perfor-
mance requirements for very fast acceleration or deceleration? If so, the
inertia and gearing of the system will have to be used to determine the
additional torque requirements.
Application Notes I19

Isolation Transformer

I I
Line Disturbances Harmonics IGBT Harmonics,Notching
Harmonics, Notching
CSI, WI

Figure 10-1 AC vs DC Comparisons

Friction Toque(lbft) = Force(lb) x Radius(ft)

Reflected friction torque varies inversely with the gear ratio.

Inertia(wk*) x change in rpm
Accel Toque
308 x time(seconds)

Reflected accel torque varies inversely as the square of the gear ratio.
120 Variable Speed Drive Fundamentals

Speed
What is the maximum speed required? Is this at full torque or in a
lightly loaded condition?
Horsepower. Using the sum of the torques calculated above, and the
maximum speed requirement, calculate the horsepower requirement.
Torque(1bft) x Maximum Speed
Horsepower =
5252

If the highest torque requirements are very short in duration, and

within overload capabilities of the drive, it is acceptable to size the
drive within those limits. It is important to be aware that too many over-
loads in a short time may exceed the thermal capacity of the motor and/
or its drive.
Sometimes, a small change in gear ratio may optimize the speed
torque needs, and allow use of a smaller drive. These items will become
more apparent as we further analyze the machine. The following ques-
tions should be considered as a check list.
Machine Starting Issues
Will the machine operate automatically, or from an operator’s
control station?
If from operator’s station, what device will be used?
- Push-button and potentiometer
- Drum controller
- Joy-stick (master switch)
If automatic, what is source of start control?
- Float switch
- Pressure switch
- Clock
- Thermostat
- Interlock from another machine
- PLC, computer, NC, etc.
What special safety precautions are required for any automatic
operations to prevent false starts or damage?
How often will the machine start?
What is starting torque?
Application Notes 121

What is machine inertia?

How much time is required for starting?
Is a smooth start required?
Under what conditions will the machine start?
- Loaded
- Unloaded
- Varying

Stopping Considerations
Operator controlled, or automatic?
Is a quick stop required? (Inertia?)
Is an accurate stop required?
Should E-Stop be quick, or coast-to-stop?
Is a mechanical brake required?
Reversal Considerations
Does normal operation require periodic reversals?
How often are these reversals required?
Is the function basically the same, forward and reverse?
Is the operation generally in one direction, but requires emer-
gency reversal for maintenance, jams, etc.?
Running Conditions
Is the machine run at essentially a single constant speed?
Does it have two or more constant speeds?
Is variable speed required?
Over what range?
Is speed preset or adjustable while running
Does speed vary through different parts of a cycle?
Must the speed hold constant with varying load, or can the
speed change with load?
Is there a slow-down required during any part of the cycle?
Is slow-down abrupt or soft? (inertia, dynamic brake?)
Environment
What are the ambient conditions where the equipment is to be
installed?
Hot or cold (See Chapter 11)
122 Variable Speed Drive Fundamentals

Wet or dry
Dusty (conductive ?)
Corrosive
High altitude (cooling?)
Controlled atmosphere, humidity, temperature?
Size limitations
Motors
Is an existing motor being used?
Get entire nameplate information.
Request resistance and megger readings to determine the condi-
tion of the motor.
Take ammeter readings under various operating conditions to
verify suitability for intended operation.
Special Features
What features do we need for a NEW Motor?
Horsepower AC or DC
Base speed.
Maximum speed if constant horsepower application.
Enclosure type
Mounting position, J-box position
- Vertical
- Horizontal
- Feet or flange
- C or D flange
Tachometer or other feed-back
Brake
Heaters
Winding thermostat
Blower
System Voltage
Protective Features Required
Overload
Field loss
Tachometer loss
* Phase loss
Overspeed
Overtemperature, controller and/or motor
Application Notes 123

Safety interlocks to other equipment

Monitoring Requirements
Diagnostics
Circuit checker
Load meter, scale?
Speed meter, scale?
Ammeter(s)
Voltmeter(s)

List those supplied by customer.

Identify those supplied with drive.
What signal levels will be supplied for reference?
- 4 to 10 ma
- 0 to 5 vdc
- + and - 10 vdc
- pulse train
PLC?
Construction
- Open panel
- NEMA type
Power Source
Utility or local source?
Volts, phase, Hz
Is isolation transformer or inductor required? If so, supplied by
whom?
Are disconnect switches required?
- Fused or unfused?
- Circuit breaker?
Operator
- Flange mounted
- Through-the-door
Loose /ferns To Include
Push buttons, lamps, selector switches
Relays, starters, PLC hardware
Joy-stick controller(s)
Potentiometer(s)
Transducers
 Variable Speed Drive Fundamentals

SUGGESTED GROUNDING
SYSTEM TO MINIMIZE E.M.I.

ix
NOISE
(NOISE SOURCES!I)

iROUND BOTH
EM1 :NDS POWER
SHIELD
, .......

4 I,
,
,

,
,,

,
I
!
;
,
!MOTOR F R A M E
,,
I

I
,,

I
I
,
,
!

..
! ......;

-
- COMMON GROUND
TREAT T A C H O M E T E R MOTOR FIELD LEADS
S A M E A S POT S H O W N ABOVE. ARE C O N S I D E R E D P O W E R LEADS.
AND A NOISE SOURCE.

Figure 10-2 EM1 Grounding

Wiring Concerns
Electro-magnetic Interference (E.M.I.) is radiated by electronic drive
systems. Proper shielding and grounding practices should be followed to
minimize and protect sensitive circuits from E.M.I. noise. Figure 10-2
illustrates several ways of controlling EMI. These are valid for both AC
and DC drive systems. If cabinet doors and subpanels are not properly
bonded they might act as antennas and actually amplify the EMI.
One consideration that is often overlooked is the effect of voltage
drop on the variable voltage power conductors between the control cab-
inet and the motor. Excess voltage drop will cause speed regulation
problems and torque loss in both DC and AC systems. (Figure 10-3.)
Article 430 of the National Electrical Code (NEC), and Tables 430-
149 and 430-150 give instructions for sizing conductors for motor ser-
Application Notes 126

INVERTER AC M O T O R
460 v 450.8 v
r
9.2volts drop = 2% 96 %
6o hz loo%, TORQUE

230 v 220.8 v
30 hz 9.2volts drop = 4% 92 %
50% TORQUE

hz 9.2volts drop = 20% 64 %

10% TORQUE

ASSUME CONSTANT CURRENT

Figure 10-3 Torque vs Voltage Drop

vice. The requirement is that conductor ampacity must be 125% of

nameplate current, or 150% of the table values if nameplate data is
unavailable. NEC wire tables are designed to prevent conductor over-
heating, and do not adequately consider torque degradation from line
voltage drop. The ampacity ratings are acceptable minimums ifthe wire
run is not too long, Present day installations often consolidate drive
packages in a common control room, with motors actually installed hun-
dreds of feet away. If the voltage drop at full load and speed exceeds
1%, conductor sizes should be increased beyond the NEC requirements.
Constant torque loads will draw the same current at 10% speed as
at 100%. This means that the IR (voltage) drop will be constant. If the
voltage drop is 2% at full speed and voltage, it will be 20% at 10%
speed. The torque on an AC motor will be reduced to about 64% at this
low speed. A DC motor will lose 20% of rated speed, or the tachometer
control will have to force excess current (heat?) to compensate for the
speed and torque losses.
It never pays to skimp on conductor sizes on any variable voltage
power circuit,
126 Variable Speed Drive Fundamentals

SUMMARY
The foregoing information is offered as “food for thought” to raise
flags for items that might be missed in a quick inspection of an applica-
tion.
It is important to watch for special operational nuances where there
is interaction between related drives. These might be slight variations in
spacing of product, timing arrival into a specific position, momentary
accel/decel cycles. Sometimes you will find that as a conveyor unloads
onto the next section, there may be a moment of “pullyythat may require
dynamic braking option for an AC drive. Some saws will pull lumber
faster than it is fed.
Sudden step-change reductions in speed often require the dynamic
braking option as the inertia of the system may momentarily “over-
drive’, the motor.
In other words, get a “feel” for how the machine performs. A drive
should make the machine operate as designed, not limit the machine to
performance of a misapplied drive.