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MOTOR FORMULAS AND CALCULATIONS

The formulas and calculations which appear below should be used for estimating purposes only. It is the responsibility of
the customer to specify the required motor Hp, Torque and accelerating time for his application. The salesman may wish
to check the customers specified values with the formulas in this section, however, if there is serious doubt concerning
the customers application or if the customer requires guaranteed motor/application performance, the customer should
engage an electrical engineer to do the exact calculations.

For a detailed explanation of each formula, Click on the links below to go right to it.

Rules Of Thumb Approximation

Mechanical Formulas
Temperature Conversion
High Inertia Loads
Synchronous Speed, Frequency And Number
Of Poles Of AC Motors
Relation Between Horsepower, Torque, And
Speed
Motor Slip
Symbols
Equivalent Inertia
Electrical Formulas
Locked Rotor Current (IL) From Nameplate
Data
Effect Of Line Voltage On Locked Rotor
Current (IL) (Approx.)
Basic Horsepower Calculations
Accelerating Torque
Duty Cycles

Rules Of Thumb (Approximation)

At 1800 rpm, a motor develops a 3 lb.ft. per hp

At 1200 rpm, a motor develops a 4.5 lb.ft. per
hp
At 575 volts, a 3-phase motor draws 1 amp per
hp
At 460 volts, a 3-phase motor draws 1.25 amp
per hp
At 230 volts a 3-phase motor draws 2.5 amp
per hp
At 230 volts, a single-phase motor draws 5
amp per hp
At 115 volts, a single-phase motor draws 10
amp per hp

Mechanical Formulas

Torque in lb.ft. = HP x 5250 ----- HP = Torque x rpm ----- rpm = 120 x Frequency
 rpm 5250 No. of Poles

Temperature Conversion

Deg C = (Deg F - 32) x 5/9

Deg F = (Deg C x 9/5) + 32

Temperature Conversion Formula

ºR = 1.8 K + 0.6º ºC = 5/9 (ºF-32º) ºC = Celsius, degrees

ºF = Fahrenheit, degrees
.K = 5/ 9 (ºR-0.6º)
ºR = ºF + 460º
.K = Kelvin
ºF = 1.8ºC + 32º .K = ºC + 273º
ºR = Rankine, degrees

to ºC Temp. to ºF to ºC Temp. to ºF to ºC Temp. to ºF

-17.8 0 32.0 371.1 700 1292.0 760.0 1400 2552.0

10.8 50 122.0 398.9 750 1382.0 787.8 1450 2642.0
37.8 100 212.0 426.7 800 1472.0 815.6 1500 2732.0
65.6 150 302.0 454.4 850 1562.0 843.3 1550 2822.0
93.3 200 392.0 482.2 900 1652.0 872.1 1600 2912.0

121.0 250 482.0 510.0 950 1742.0 899.9 1650 3002.0

148.9 300 572.0 537.8 1000 1832.0 927.7 1700 3092.0
176.7 350 662.0 565.6 1050 1922.0 955.4 1750 3182.0
204.4 400 752.0 593.3 1100 2012.0 983.2 1800 3272.0
232.2 450 842.0 621.1 1150 2102.0 1011.0 1850 3362.0
260.0 500 932.0 648.9 1200 2192.0 1038.8 1900 3452.0
287.7 550 1022.0 676.7 1250 2282.0 1066.6 1950 3542.0
315.6 600 1112.0 704.4 1300 2372.0 1094.3 2000 3632.0
343.3 650 1202.0 732.2 1350 2462.0 1121.1 2050 3722.0

High Inertia Loads

WK2 x rpm
t=
308 x T av. WK2 = inertia in lb.ft.2
----- t = accelerating time in sec.
WK2 x rpm T = Av. accelerating torque lb.ft.
T=
308 x t
Load rpm
inertia reflected to motor = Load Inertia 2
Motor rpm

Synchronous Speed, Frequency And Number Of Poles Of AC Motors

120 x f P x ns 120 x f
ns = ----- f = ----- P =
P 120 ns

Relation Between Horsepower, Torque, And Speed

Txn 5250 HP 5250 HP

HP = ----- T = ----- n =
5250 n T
Motor Slip

ns - n
% Slip = x 100
ns
Code kVA/HP Code kVA/HP Code kVA/HP Code kVA/HP

A 0-3.14 F 5.0 -5.59 L 9.0-9.99 S 16.0-17.99

B 3.15-3.54 G 5.6 -6.29 M 10.0-11.19 T 18.0-19.99

C 3.55-3.99 H 6.3 -7.09 N 11.2-12.49 U 20.0-22.39

D 4.0 -4.49 I 7.1 -7.99 P 12.5-13.99 V 22.4 & Up

E 4.5 -4.99 K 8.0 -8.99 R 14.0-15.99

Symbols

I = current in amperes
E = voltage in volts
kW = power in kilowatts
kVA = apparent power in kilo-volt-amperes
HP = output power in horsepower
n = motor speed in revolutions per minute (RPM)
ns = synchronous speed in revolutions per minute (RPM)
P = number of poles
f = frequency in cycles per second (CPS)
T = torque in pound-feet
EFF = efficiency as a decimal
PF = power factor as a decimal

Equivalent Inertia

In mechanical systems, all rotating parts do not usually operate at the same speed. Thus, we need to determine the
"equivalent inertia" of each moving part at a particular speed of the prime mover.

The total equivalent WK2 for a system is the sum of the WK2 of each part, referenced to prime mover speed.

The equation says:

Npart
WK2EQ = WK2part 2
Nprime mover

This equation becomes a common denominator on which other calculations can be based. For variable-speed devices,
inertia should be calculated first at low speed.

Let's look at a simple system which has a prime mover (PM), a reducer and a load.

WK2 = 900 lb.ft.2

WK2 = 100 lb.ft.2 WK2 = 27,000 lb.ft.2
(as seen at output shaft)
 PRIME MOVER 3:1 GEAR REDUCER LOAD

The formula states that the system WK2 equivalent is equal to the sum of WK2parts at the prime mover's RPM, or in this
case:

Red. RPM Load RPM

WK2EQ = WK2pm + WK2Red. 2 + WK2
Load
2
PM RPM PM RPM

Note: reducer RPM = Load RPM

1 1
WK2EQ = WK2pm + WK2Red. 2 + WK2Load 2
3 3

The WK2 equivalent is equal to the WK2 of the prime mover, plus the WK2 of the load. This is equal to the WK2 of the
prime mover, plus the WK2 of the reducer times (1/3)2, plus the WK2 of the load times (1/3)2.

This relationship of the reducer to the driven load is expressed by the formula given earlier:

Npart
WK2EQ = WK2part 2
Nprime mover

In other words, when a part is rotating at a speed (N) different from the prime mover, the WK2EQ is equal to the WK2 of
the part's speed ratio squared.

In the example, the result can be obtained as follows:

The WK2 equivalent is equal to:

1 1
WK2EQ = 100 lb.ft.2 + 900 lb.ft.2 2 + 27,000 lb.ft.2 2
3 3

Finally:

WK2EQ = lb.ft.2pm + 100 lb.ft.2Red + 3,000 lb.ft2Load

WK2EQ = 3200 lb.ft.2

The total WK2 equivalent is that WK2 seen by the prime mover at its speed.

Electrical Formulas (For more formulas see "Formulas")

Alternating Current
To Find
Single-Phase Three-Phase
HP x 746 HP x 746
Amperes when horsepower is known
E x Eff x pf 1.73 x E x Eff x pf
kW x 1000 kW x 1000
Amperes when kilowatts are known
E x pf 1.73 x E x pf
 kVA x 1000 kVA x 1000
Amperes when kVA are known
E 1.73 x E
I x E x pf 1.73 x I x E x pf
Kilowatts
1000 1000
IxE 1.73 x I x E
kVA
1000 1000

I x E x Eff x pf 1.73 x I x E x Eff x pff

Horsepower = (Output)
746 746

I = Amperes; E = Volts; Eff = Efficiency; pf = Power Factor; kVA = Kilovolt-amperes; kW = Kilowatts

Locked Rotor Current (IL) From Nameplate Data

577 x HP x kVA/HP
Three Phase: IL =
E
See: kVA/HP Chart
1000 x HP x kVA/HP
Single Phase: IL =
E

EXAMPLE: Motor nameplate indicates 10 HP, 3 Phase, 460 Volts, Code

F.
577 x 10 x (5.6 or 6.29)
IL =
460

IL = 70.25 or 78.9 Amperes (possible range)

Effect Of Line Voltage On Locked Rotor Current (IL) (Approx.)

ELINE
IL @ ELINE = IL @ EN/P x
EN/P

EXAMPLE: Motor has a locked rotor current (inrush of 100 Amperes (IL) at the rated nameplate voltage
(EN/P) of 230 volts.

What is IL with 245 volts (ELINE) applied to this motor?

IL @ 245 V. = 100 x 254V/230V

IL @ 245V. = 107 Amperes

Basic Horsepower Calculations

Horsepower is work done per unit of time. One HP equals 33,000 ft-lb of work per minute. When work is done by a source
of torque (T) to produce (M) rotations about an axis, the work done is:

radius x 2 x rpm x lb. or 2 TM

When rotation is at the rate N rpm, the HP delivered is:

 radius x 2 x rpm x lb. TN
HP = =
33,000 5,250

For vertical or hoisting motion:

WxS
HP =
33,000 x E

Where:

W = total weight in lbs. to be raised by motor

S = hoisting speed in feet per minute
E = overall mechanical efficiency of hoist and gearing. For purposes of estimating
E = .65 for eff. of hoist and connected gear.

For fans and blowers:

Volume (cfm) x Head (inches of water)

HP =
6356 x Mechanical Efficiency of Fan

Or

Volume (cfm) x Pressure (lb. Per sq. ft.)

HP =
3300 x Mechanical Efficiency of Fan

Or

Volume (cfm) x Pressure (lb. Per sq. in.)

HP =
229 x Mechanical Efficiency of Fan

For purpose of estimating, the eff. of a fan or blower may be assumed to be 0.65.

Note:Air Capacity (cfm) varies directly with fan speed. Developed Pressure varies with square of fan speed. Hp varies
with cube of fan speed.

For pumps:

GPM x Pressure in lb. Per sq. in. x Specific Gravity

HP =
1713 x Mechanical Efficiency of Pump

Or

GPM x Total Dynamic Head in Feet x Specific Gravity

HP =
3960 x Mechanical Efficiency of Pump

where Total Dynamic Head = Static Head + Friction Head

For estimating, pump efficiency may be assumed at 0.70.

Accelerating Torque

The equivalent inertia of an adjustable speed drive indicates the energy required to keep the system running. However,
starting or accelerating the system requires extra energy.

The torque required to accelerate a body is equal to the WK2 of the body, times the change in RPM, divided by 308 times
the interval (in seconds) in which this acceleration takes place:

WK2N (in lb.ft.)

ACCELERATING TORQUE =
308t

Where:

N = Change in RPM
W = Weight in Lbs.
K = Radius of gyration
t = Time of acceleration (secs.)
WK2 = Equivalent Inertia
308 = Constant of proportionality

Or

WK2N
TAcc =
308t

The constant (308) is derived by transferring linear motion to angular motion, and considering acceleration due to gravity.
If, for example, we have simply a prime mover and a load with no speed adjustment:

Example 1

PRIME LOADER LOAD

WK2 = 200 lb.ft.2 WK2 = 800 lb.ft.2

The WK2EQ is determined as before:

WK2EQ = WK2pm + WK2Load

WK2EQ = 200 + 800

WK2EQ = 1000 ft.lb.2

If we want to accelerate this load to 1800 RPM in 1 minute, enough information is available to find the amount of torque
necessary to accelerate the load.

The formula states:

WK2EQN 1000 x 1800 1800000

TAcc = or or
308t 308 x 60 18480

TAcc = 97.4 lb.ft.

In other words, 97.4 lb.ft. of torque must be applied to get this load turning at 1800 RPM, in 60 seconds.
Note that TAcc is an average value of accelerating torque during the speed change under consideration. If a more
accurate calculation is desired, the following example may be helpful.

Example 2

The time that it takes to accelerate an induction motor from one speed to another may be found from the following
equation:

WR2 x change in rpm

t=
308 x T

Where:

T = Average value of accelerating torque during the speed change under consideration.
t = Time the motor takes to accelerate from the initial speed to the final speed.
WR2 = Flywheel effect, or moment of inertia, for the driven machinery plus the motor rotor in lb.ft.2 (WR2 of driven
machinery must be referred to the motor shaft).

The Application of the above formula will now be considered by means of an example. Figure A shows the speed-torque
curves of a squirrel-cage induction motor and a blower which it drives. At any speed of the blower, the difference between
the torque which the motor can deliver at its shaft and the torque required by the blower is the torque available for
acceleration. Reference to Figure A shows that the accelerating torque may vary greatly with speed. When the speed-
torque curves for the motor and blower intersect there is no torque available for acceleration. The motor then drives the
blower at constant speed and just delivers the torque required by the load.

In order to find the total time required to accelerate the motor and blower, the area between the motor speed-torque curve
and the blower speed-torque curve is divided into strips, the ends of which approximate straight lines. Each strip
corresponds to a speed increment which takes place within a definite time interval. The solid horizontal lines in Figure A
represent the boundaries of strips; the lengths of the broken lines the average accelerating torques for the selected speed
intervals. In order to calculate the total acceleration time for the motor and the direct-coupled blower it is necessary to
find the time required to accelerate the motor from the beginning of one speed interval to the beginning of the next
interval and add up the incremental times for all intervals to arrive at the total acceleration time. If the WR2 of the motor
whose speed-torque curve is given in Figure A is 3.26 ft.lb.2 and the WR2 of the blower referred to the motor shaft is 15
ft.lb.2, the total WR2 is:

15 + 3.26 = 18.26 ft.lb.2,

And the total time of acceleration is:

WR2 rpm1 rpm2 rpm3 rpm9

+ + +---------+
308 T1 T2 T3 T9

Or

18.26 150 150 300 300 200 200 300 100 40

t= + + + + + + + +
308 46 48 47 43.8 39.8 36.4 32.8 29.6 11

t = 2.75 sec.

Figure A
Curves used to determine time required to accelerate induction motor and blower

Accelerating Torques
T1 = 46 lb.ft. T4 = 43.8 lb.ft. T7 = 32.8 lb.ft.
T2 = 48 lb.ft. T5 = 39.8 lb.ft. T8 = 29.6 lb.ft.
T3 = 47 lb.ft. T6 = 36.4 lb.ft. T9 = 11 lb.ft.
 Wave Form

Duty Cycles

Sales Orders are often entered with a note under special features such as:

-----"Suitable for 10 starts per hour"

Or
----"Suitable for 3 reverses per minute"
Or
-----"Motor to be capable of accelerating 350 lb.ft.2"
Or
-----"Suitable for 5 starts and stops per hour"

Orders with notes such as these can not be processed for two reasons.

1. The appropriate product group must first be consulted to see if a design is available that will perform the required
duty cycle and, if not, to determine if the type of design required falls within our present product line.
2. None of the above notes contain enough information to make the necessary duty cycle calculation. In order for a
duty cycle to be checked out, the duty cycle information must include the following:
a. Inertia reflected to the motor shaft.
b. Torque load on the motor during all portions of the duty cycle including starts, running time, stops or
reversals.
c. Accurate timing of each portion of the cycle.
d. Information on how each step of the cycle is accomplished. For example, a stop can be by coasting,
mechanical braking, DC dynamic braking or plugging. A reversal can be accomplished by plugging, or the
motor may be stopped by some means then re-started in the opposite direction.
e. When the motor is multi-speed, the cycle for each speed must be completely defined, including the method
of changing from one speed to another.
f. Any special mechanical problems, features or limitations.
Obtaining this information and checking with the product group before the order is entered can save much time, expense
and correspondence.

Duty cycle refers to the detailed description of a work cycle that repeats in a specific time period. This cycle may include
frequent starts, plugging stops, reversals or stalls. These characteristics are usually involved in batch-type processes and
may include tumbling barrels, certain cranes, shovels and draglines, dampers, gate- or plow-positioning drives,
drawbridges, freight and personnel elevators, press-type extractors, some feeders, presses of certain types, hoists,
indexers, boring machines, cinder block machines, key-seating, kneading, car-pulling, shakers (foundry or car), swaging
and washing machines, and certain freight and passenger vehicles. The list is not all-inclusive. The drives for these loads
must be capable of absorbing the heat generated during the duty cycles. Adequate thermal capacity would be required in
slip couplings, clutches or motors to accelerate or plug-stop these drives or to withstand stalls. It is the product of the
slip speed and the torque absorbed by the load per unit of time which generates heat in these drive components. All the
events which occur during the duty cycle generate heat which the drive components must dissipate.

Because of the complexity of the Duty Cycle Calculations and the extensive engineering data per specific motor design
and rating required for the calculations, it is necessary for customer to refer to an electrical engineer for motor sizing with
a duty cycle application.

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