Welcome to the dimensioning of low-voltage AC drives web course.

In this first
module, we’ll cover basic information related to dimensioning low-voltage AC drives.

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After completing this module, you will be able to:
•Describe the operation and properties of motors and inverters,
•identify motor behavior and
•describe the loadability of an AC motor.

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There are several reasons why the AC motor is suitable for industrial
applications. The AC motor is the main reason for using an AC drive.
Asynchronous motors and synchronous permanent magnet motors are
completely enclosed. These motors can be installed in harsh
environments. In most cases a standard AC motor can be used. These
motors are nearly maintenance-free.

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This is the torque-speed curve of an AC motor. The positive part of this
curve is the motoring mode, and the negative curve is the generator
mode. The shape of the curve is similar in both modes.
•In generator mode, the motor feeds current to the supply.
•The nominal torque of the motor is created with the nominal slip. The
nominal torque is illustrated by the dot.
•The speed at point 1 is the synchronous speed.
Friction in the bearings and the cooling fan causes a slight slip without a
load. When using speed control, a frequency converter compensates for
the error in speed due to the slip.
•The motor only functions correctly below the maximum torque value
Tmax.
•If the torque exceeds the Tmax value, the current increases to a high
value and the rotor will stop.

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The shape of the AC motor’s torque curve is similar in each of the four
quadrants. It can operate in motor and generator modes in both rotation
directions. When the frequency converter controls the speed of the motor,
the torque curve will remain the same in each speed point up to the
nominal speed of the motor. In comparison, a direct online motor can
have one torque curve. When going over the nominal speed point, the
maximum torque of the motor decreases.

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The flux of the motor is inversely proportional to the speed beyond the
field weakening point. The maximum torque of the motor decreases
quadratically.

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Power is proportional to the speed and torque. If the current in the field
weakening area is constant, the load torque decreases inversely to the
speed, because the voltage value remains constant.

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The continuous load of the motor must stay below the loadability curve.
By using a separate cooling fan, it is possible to run the motor below
the nominal speed at 100% load. Above the nominal speed, the
continuous loadability of the motor decreases inversely to the speed,
because the flux of the motor decreases.

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We’ll now move on to the second portion of the module.
This portion covers:
•the basic idea of torque, flux, current, speed and their relationships,
•The influence of the field weakening point to dimensioning,
•Loadability curves of the motor,
•The use of dimensioning formulas and loadability curves,
•More exact dimensioning is done with the DriveSize PC tool,
•Different kinds of application types will be introduced.

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After completing this portion, you’ll be able to:
•Use the correct dimensioning procedure,
•Do manual calculations of basic drive systems,
•Use the dimensioning formulas provided,
•Select the correct load type for the application,
•Select a drive and motor from the catalogs, and
•Calculate and select a supply unit.

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From the dimensioning point of view there are two kinds of drive
systems, single drives and multidrives.
•In multidrives, several inverters are connected to the same DC-bus.
•In single drives, there is only one inverter and supply unit. With single
drives, it is not necessary to dimension the supply unit separately.

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The dimensioning procedure goes ahead from the load, motor and
frequency converter, and in multidrives, additionally, the supply unit
and transformer.
•First of all, network information and the electrical load of the motor
must be known.
•The load can be given as a power value or a torque value.
•The correct type of motor and converter are selected by using the
catalogues

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The formulas used when manually dimensioning a drive system are
speed, slip, power, torque and flux. The formulas most often used are
the equations for shaft power and torque. They provide the
relationships between torque, speed and power

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Here are two actual loadability curves of a motor. The motor continuous
load must stay below the loadability curve. Momentarily, the motor can
be loaded over the loadability curve. To properly dimension the system,
this load must be separately checked.

Here for example, a separate cooling fan could solve the problem of
temperature rise. Dimensioning for temperature class F a smaller motor
may be selected, but the consequence will be that the lifetime of the
motor can be shorter and the time intervals between lubrications will be
shorter. Temperature class B is normally used in dimensioning.

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The available output voltage at frequencies beyond the field weakening
point varies according to the type of frequency converter used. The
voltage in the field weakening area depends on the rectifier, the reactor,
switching frequency, and so on.

If dimensioning is done manually, a voltage correction factor should be

used in the field weakening area when calculating the selection current
of the inverter. The DriveSize PC tool automatically uses the correct
voltage in dimensioning calculations.

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This graph illustrates the maximum available short-term torque of a
motor, and its breakdown torque. The breakdown curve specifies the
point when the motor no longer operates correctly. A margin should be
left between it and the maximum load torque. Here, IC411 is a self-
ventilated motor. IC416 is a force-ventilated motor.

The continuous loadability of the force-ventilated motor is 100% below

the field weakening point. The field weakening starts from 90% of the
synchronous speed. The synchronous speed is the 1.0 value.

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Certain application data must be known to dimension the units: the
supply and motor voltage, speed range, motor maximum continuous
load and overload requirement.

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When selecting the motor, its thermal dimensioning and maximum load
torque should be checked. A pole number must be selected to be able
to set the speed range for the loadability curve. In high-speed
applications, the maximum allowed motor speed should not be
exceeded.

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When selecting the inverter, the load type must be decided. Current
value definitions are different depending on the load type. The current
values given for the load type in the inverter catalog must not be
exceeded.

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The current value for selecting the inverter is calculated based on the
rated motor current and the load torque below the field weakening
point. If the maximum continuous load of the motor is less than its
nominal load given in the catalog, the nominal current of the inverter
can then be less than the nominal current of the motor. Normally this
simplified formula can be used to calculate the inverter current.

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Above the field weakening point, the current calculation is based on the
power values. The voltage reduction factor “k” must be considered
when a diode or thyristor supply is used. This simplified formula can be
used.

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The total power of the supply unit is the sum of all the motoring and
generating powers of the motors, multiplied by the efficiency factor. The
efficiency factor takes into account the efficiency of the motor and
inverter. In this example formula, some motors are motoring, and some
are generating.

The selection of the diode supply unit or thyristor supply unit is made
according to the calculation for the needed DC current. The current
values of specific duty cycles are listed in the product catalog.

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The selection of the IGBT suppy unit is done according to the needed
AC current. The ISU can give full motor power and voltage at a low line
voltage, within certain tolerances. This is a benefit when dimensioning a
motor and inverter.

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In selecting a transformer, an additional factor (1.2) is used to take into
account the efficiency, power factor, transformer loadability and the
voltage drop. The data for the exact formula should be taken from the
transformer name plate or the manufacturer’s data sheets.

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Listed here are general de-rating values for motors and inverters.
Typically, 100% loadability is allowed up to 40ºC and up to an altitude of
1000 m. De-rating values are different for different types of drives. The
exact values can be found in product catalogs.

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We’ll now consider some application types. Pumps and fans have a
squared torque-load curve. The maximum speed is normally set close
to the field weakening point in pump and fan applications. At low
speeds, the load is small. An additional cooling fan is normally not
needed for the motor.

In constant-torque applications, an additional fan is often a good

solution to increase the loadability at low speeds. Gear boxes efficiently
optimize the motor power. Typical constant-torque applications are
conveyors, roller-tables, elevators and crane drives, feeders, screws,
compressors, extruders and cement kilns.

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Winders, coilers and rollers have a constant-power load curve. The
maximum speed can be set to the field weakening area. Typically, self-
ventilation is enough to cool the motor. The ability to overload the motor
should be determined.

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Thank you for viewing this presentation.

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