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faq237-1224
Posted: 20 Mar 06 (Edited 9 Jul 06)
Due to the frequent questions about running motors at "the other frequency" this FAQ was created.
This FAQ is directed at other engineers and so will contain details the average user may not care
about. You are invited to pay attention only to what is useful to you.
This FAQ applies to induction motors, both single, and polyphase. Single phase motors have an added
aspect that will be discussed at the end of this FAQ.
AC motors are quite complex for all their functional simplicity - turn them on they spin.
There are a huge number of interacting relationships in a motor's design. There are first order, second
order and probably even third order aspects that are all balanced to produce a dependable motor with the
desired characteristics.
This FAQ will deal only with the First Order aspects.
If the motor slows down its cooling will drop (and at a faster rate than the slowdown).
If the motor speeds up its cooling will increase rapidly.
If the frequency drops the V/Hz goes up. This means that the motor needs a larger magnetic circuit.
Without it the magnetic circuit can saturate. This leads to a rapid increase in current draw and a
corresponding large increase in temperature. (A motor's chief enemy)
If the frequency increases the V/Hz drops. This is not a first order consideration. [The motor may have a
worse power factor.]
A motor is a device that 'wants' to turn at its designed speed, set by its designed operating frequency. It
delivers the required horsepower (hp) the load needs when the load is spun at the motor's designed
speed. Different loads change their hp demands in very different manners, depending on the type of load
they are.
If a motor's load increases for some reason the motor will be slowed, this means the back-emf drops; this
causes the motor to draw more current. More current is where the motor gets more power to turn the
heavier load. Here the prudent motor user makes sure that the motor is pulling less current then the
motor's full load amperage (FLA) rating.
If the load remains the same and the voltage is lowered the motor will draw more current to continue
meeting the load's hp requirement. Remember the motor will still be running at the same speed since the
frequency wasn't changed.
You should discuss what the load will do when sped up 20% with someone knowledgeable with that type
of load. (Forum members are very knowledgeable in this aspect!)
If the load can take the speed increase then run the load and promptly check the motor's current draw. If
it is under the FLA you should have no other problems.
Make sure the load will still do what is required of it when running slower. For instance, a fan load would
now move less air. Still enough?
The cooling will reduce dramatically. Is it enough to matter? This depends on how the load has
decreased. If the hp requirement dropped because the load has decreased the current will drop and less
heat will be released internally. You would want to take temperature measurements until the motor
reaches a steady state temperature running in its new frequency application.
The motor's hp will drop because hp is a function of speed x torque. The motor's torque doesn't change
but its speed has dropped so it is now a lower hp motor. If you change pulley sizes to return the load to its
original speed your motor will likely be undersized, possibly seriously. Example: A 10 hp motor is now an 8
hp.
The most serious issue is the V/f issue. The V/f will increase. Likely enough to cause a large increase in
the motor's current. This coupled with the reduced cooling may cause rapid overheating. However the V/f
problem can be fully mitigated! You reduce the voltage to the motor by the amount required to return the
V/f back to its original value. This removes the hazard of excess current from an increased V/f.
Some single phase motors have start or run capacitors and some both. If the motor is being shifted from
50 to 60Hz then their effect will increase. This will usually pose no problem.
Alternatively, taking a motor from 60 to 50Hz will reduce the capacitor effects. This will result in possibly
lower running and starting torques. This may mean the motor cannot successfully start its load or maintain
running a load.
A failure to start may result in a rapid burnout (seconds) so this should be carefully monitored
initially. Larger capacitors or additional ones may be needed.
If you need any other clarifications please post a clear and specific question in the Electric Motors forum
and members will be happy to assist you..
If you see a need for a correction or an addition in this FAQ please let me know in a thread or directly.
Keith Cress
Flamin Systems, Inc.- http://www.flaminsystems.com