Compatibility of Motors and VFD’s

Before any 3 phase motor is powered from a VFD (variable frequency drive), the questions listed below
must be answered. The guidelines referenced are published in many of Regal’s motor catalogs.
Compliance with these guidelines ensures compatibility of the motor and VFD.

Question #1: Is the motor able to power the load or will it stall?
Answer: The customer must match the driven load requirements with the motor and VFD capabilities to
prevent stalling of the motor and tripping of the VFD.
All 3 phase Regal General Purpose motors can produce >180% of rated torque between zero RPM and
base RPM, and rated HP (constant HP) from base RPM to at least 125% of base RPM. To avoid stalling
and VFD trips beyond base speed, the required load torque must decrease at a linear (constant power) rate.
High overloads beyond base speed may cause the motor to stall (or the VFD to fold back frequency to
prevent stalling). Contact the factory whenever overload torque is required at speeds higher than the 115%
of motor base speed.
Definite Purpose Vector Duty motors can produce >250% torque between zero RPM and base RPM, and
rated HP from base RPM to 150% - 400% of base RPM (depending on motor design).
Available peak motor torque is determined primarily by the ampacity of the VFD and VFD tuning
parameters. Over sizing the VFD will allow the motor to produce >200% torque between zero RPM and
base RPM. Using a vector type VFD (either open loop or closed loop) is essential for the motor to produce
optimal torque, especially at low speeds. The VFD must provide a clean waveform (<~5% total harmonic
voltage distortion [%THD]) and must be properly adjusted (tuned to match the motor).

Question #2: Will the motor overheat?

Answer: Overheating is most commonly caused by:
1. Applying incorrect voltage to the motor; A motor will overheat if the VFD produces too high of
voltage, too low of voltage, or a waveform that is significantly distorted (compared to a clean sine
wave). To avoid overheating, the VFD must be programmed to match the motor nameplate data,
voltage boost at low frequencies must stay within the motor limits, and % voltage THD should be
limited to ~5%. Setting the VFD’s carrier frequency to 3 kHz (or equivalent) normally produces a
voltage waveform with distortion less than 5% THD. Vector type VFD's designed after 1995,
such as those made by ABB, AC Tech, Automation Direct, Avtron, Bardac, Bosch Rexroth,
Control Techniques, Danfoss, Delta, Eaton, Fuji, Hitachi, Mitsubishi, Parker SSD, Rockwell,
Siemens, Square D, Sumitomo, Toshiba, Unico, Vacon, Yaskawa, etc. apply the proper voltage
boost and produce waveforms with distortion less than 5% THD. VFD's designed prior to 1995 or
those with carrier frequency less than 2 kHz should be reviewed on a case by case basis.

2. Overloading the motor (requiring too much torque for too long of a time); Although motors often
produce >150% of rated torque periodically without problem, the RMS torque required by the
driven load should not exceed the motor’s rated torque within the approved speed range. The
chart below lists continuous duty speed ranges for motors operated at rated torque. To prevent
overheating, the motor should not be operated outside the limits of this chart for more than ~5
minutes (48- 145T frame motors) to ~10 minutes (182T-256T) to ~ 20 minutes (284T and larger
motors) at a time.

3. Reduction of effective cooling air supplied to the motor; Altitudes >3300 ft reduce density of the
cooling air, operating in an ambient >40 C adds to total motor temperature, and clogged motor air
inlets or broken/clogged cooling fins reduce cooling of the motor. Operating DP or TEFC motors
at low speeds also reduces cooling and will contribute to motor overheating. Acceptable speed
ranges are listed in the table below. To illustrate, the red highlights show that a 256T frame
TEFC NEMA Premium motor will not overheat if operated between 6 and 60 Hz (10:1 speed
range) on a variable torque load or 3 to 60 Hz (20:1 range) on a constant torque load. In reality,
the motor will not overheat on a variable torque load if operated from 60 Hz down to zero RPM.
10:1 speed range was simply chosen as a default value when the chart was created.
Question #3: Will the VFD’s common mode voltage damage the motor bearings?
Answer: All VFD's on the market produce an unbalanced output voltage (a common mode voltage). Unless
a VFD is specifically designed to eliminate it or a common mode filter is added at the VFD output, this
voltage will damage the motor bearings. Economical bearing protection can be provided by adding a shaft
grounding device, such as the A500 shaft grounding kits listed in various Regal catalogs. Some Regal
motor product lines include shaft grounding devices as standard. For Division 1 motors, shaft grounding
devices may only be installed inside the motor. For Division 2 motors, only certified spark proof devices
can be installed (see application notes below). Once the VFD-sourced common mode shaft voltage is
eliminated, the bearings will be capable of reaching their calculated B-10 life. See Source of Bearing
Currents.pdf for a brief description of this phenomenon.

Question #4: Is the motor enclosure suitable for the installation?

Answer: DP or DPFV motors must be installed in clean, dry locations. TE motors with an enclosure code
of IP 43 may be installed outdoors if they are protected from rain and snow. Motors rated IP 55 or higher
can be installed directly outdoors. Division 1 motors must be labeled on the nameplate as being suitable for
VFD use, per UL. Motors used in Division 2 locations must be labeled as suitable for Division 2 (per
Regal’s policy). Before mounting a motor vertical shaft up or shaft down outdoors, make sure the motor
drains and bearing seals will provide adequate protection from water ingress.

Question #5: Will the voltage spikes from the VFD damage the motor insulation?
Answer: The fast rise time voltage pulses of the VFD stress the motor insulation. For a fast-switching
modern VFD (without dV/dT filters), the primary factors in insulation stress are VFD-to-motor cable length
and VFD carrier frequency. If the carrier frequency is set to 3 kHz (or equivalent), then the cable lengths
should be limited to the values shown below. A more complete explanation is provided in the document
MG131pub.pdf.

Submitted by Jerry Muehlbauer

Sr. Application Engineer June 18, 2012