ISA Northern California Section, South Bay

September 9, 2003

Craig Chidester
909 288 7990

How Do You Size an Adjustable Frequency Drive?

Sizing AFDs
Key elements
The The The The The The The load motor power supply environment duty cycle mounting space budget

Sizing AFDs - The Load (1)

How much starting torque?
Centrifugal pump or fan?
110% starting torque usually adequate (VT)

Conveyor?
150% starting torque (CT) Is 200% breakaway torque required?

The AFD industry conveniently has (2) ratings: 110% or 150% for 60 seconds

Sizing AFDs - The Load (2)

High inertia load (centrifuge?)
A centrifuge needs 40HP @ 1160RPM to run Centrifuge weighs 6000 lbs empty, 3 feet diameter; Wk2 = 11,760 lb-ft2 Std motor starter
650% inrush until 65% speed, set time at 30 secs 120% average torque until 65% speed

Tq = (Wk2 x N) / (308 x t) Tq = 11,760 x .65 x 1160 / 308 x 30 = 960 960 ft-lbs / 120% / 4.5 ft-lbs/HP = 178HP Voltage drop, stiction, loaded -- 200HP min

Sizing AFDs - The Load (3)

But with an AFD .
Goal is to get motor to 70% speed in 60 seconds while limiting inrush to 150% Tq = (Wk2 x N) / (308 x t) Tq = 11760 x .70 x 1160 / 308 x 60 = 517 Ftlbs 517 / 150% = 345 Ft-lbs continuous 345 ft-lbs / 4.5 ft-lbs/hp = 76 HP -- use 100HP t = 11760 x .30 x 1160 / 308 x 345 = 39 secs Total time = 60 + 39 secs = 99 secs (76 secs using 100HP)

Sizing AFDs - The Load (4)

Compare motor heating . (I r)t watt2 seconds of energy -- I t (Figure of Merit)
FV start
(650%) x 30 sec = 1267
2

AFD start
(150%) x 60 sec = 135
2

Both FofMs ignore the last part of each starting cycle which are comparable

Sizing AFDs - The motor

Sizing AFDs based on motor HP is hazardous to your pocketbook!!
AFDs are current rated - HPs are assigned Typical example, 150HP AFD is rated 189A 150HP, 450RPM motor rated 224A always check motor NP current rating And, many machinery OEMs use part of the motors service factor to reduce cost

Sizing AFDs - The power supply (1)

Voltages:
208V, 230V, 380V, 460V, 575V, 2300V, etc

Single and three phase 50 and 60 Hertz Available short circuit current
65,000A ? Higher ?

Harmonic Distortion issue?

Sizing AFDs - The power supply (2)

Harmonic distortion
IEEE-519 (latest edition) is the Guideline Typically recommends 5% THD (V and I) Point of Common Coupling (PCC) is key With 3% choke, < 35% AFD load at PCC < 5% THD(V) at 460V side Locate PCC for THD(I) on 4160V (MV) side Otherwise, spend a whole bunch of money

Sizing AFDs - The environment AFDs are rated for ambient and altitude
110% (VT) usually 40C (104F) 150% (CT) usually 50C (122F) 20% derate to get from 40C to 50C 3300 feet elevation maximum standard 3% derate per 1000 feet above 3300 100HP VT, 50C, 6000 ft = 137HP (150HP) Outdoors? Sun load adds 60 watts / Sq ft (based on maximum face dimension)

Sizing AFDs - The Duty Cycle

AFDs are rated 100% current continuously And 110% (VT) or 150% (CT) for 60 seconds in a 10 minute interval Cyclical loads that require repetitive accel torque may need to be oversized FofM for CT = I t = (150%) x 60=135
2 2

If same load is acceld in 25 secs every 2 minutes at 135%, then FofM is 227 227 / 135 -- 1.69 X base HP

Sizing AFDs - The Mounting Space

Once a rating and modifications / accessories have been established, check for space requirements!
Not all vendors are created equal Modern AFDs take less space Configurations are landscape or portrait Tradeoffs on wall space vs footprint

Sizing AFDs - The Cost

1HP -10HP -100HP -500HP --

Bare Bones $ 325 $ 1200 $ 7500 $35000

Loaded $ 2000 (1) $ 3000 (1) $30000 (2) $90000 (2)

Bare Bones: 460V, Nema 1 encl, VT Loaded: (1) Ditto plus bypass, Loaded: (2) Ditto plus bypass, MMR w / CTs and PTs, output filter and 18-pulse