Basics of ADDlying Drives

One of the biggest source of problems, in working with drive sys-

tems, is the improper application of the various drive configurations.
AC and DC drives have unique characteristics which must be consid-
ered when making your choice. Not only are there differences in torque
characteristics, but also considerable differences in costs, line distur-
bances, power-factor, motor packaging, etc. The size of the drive must
be determined on the basis of the torque required to do the job. The
horsepower can be accurately determined after the torque and speed
requirements are identified.

BASIC RELATIONSHIPS

Torque
As referenced in Chapter 2, torque is the force required to turn the
input shaft of the machine. It is usually measured in pound-feet (Ibft).
We can measure this value very simply by applying a wrench to the
input shaft and measuring the pound-feet of force it takes to move it
with a full load on the system. Measure the length of the wrench handle
in feet and, using a simple spring scale, note the value shown when the
shaft “breaks-away.” If the spring scale is attached one foot from the
shaft center, and shows a pull of 30 pounds, we have 30 Ibft of torque.
(Figure 9- 1.)
This is a force. To determine the horsepower, we must identify the
maximum speed that is required with this load.

107
108 Variable Speed Drive Fundamentals

30 LB
FORCE
LNERARM = 1 FT

TORQUE = 30 LBFT

Figure 9-1 Torque

Horsepower
Assume, in our illustration, that this shaft must turn 1750 rpm with
the 30 Ibft torque. The formula to determine HP is:
HP = torque x Rpm I5252

H P = 30 Ibft x 1750 Rpm I5252

HP= 10
Basics of Applying Drlver 109

In this illustration we have solved for the friction torque that is always
present. If the machine requires high performance, such as fast acceleration
and/or deceleration, we must add an additional torque value for the force
required to overcome the inertia of the system. This formula is:
Toque = (Inertia x change in Rpm) I(308 x Time[sec])

Inertia is expressed as Wk2 or Wr2 and can be estimated by deter-

mining the weight of the rotating mass(lbs), and multiplying by the
square of its radius@). Wr2 assumes the mass is concentrated at the
maximum radius of the object. Wk2 assumes that the mass is concen-
trated at some lesser radius, depending upon the shape of the mass.
For the purpose of illustration, we will consider that we have a 20
lb mass which is concentrated at a 9 inch radius (.75ft).
20 Ibs x (.75f = W? of 11-25lbf?.

We will assume that this requires acceleration from 0 to 1750 rpm

in 3 seconds.
Ta=(11.25Ibf?x1750rpm)/(308x3sec)=21.3Ibft

Our friction torque was 30 lbft. Add the acceleration torque of 2 1.3
lbft and we now have a total of 51.3 Ibft.
HP (51.3 x 1750) I5252 = 17.09 HP

If we can use a longer acceleration time, a 15 HP drive may do the

job. If 3 seconds is critical to the operation and frequent, then we would
consider a 20 HP drive. If the duty cycle is not too frequent, we may be
able to use a 15 HP drive and allow it to operate in an overload condition
during the high torque requirement, provided there is reasonable cooling
time between cycles. There is no reason that a motor cannot be operated
up to 150% overload for brief periods if the duty cycle is not continuous.
The smaller motor will have a lower rotor inertia, and probably have bet-
ter performance than a larger motor with higher rotor inertia.

Gear box allowance

A slow-turning machine shaft will require a gear reduction between
the motor and the shaft. The measured torque value can be divided by
I10 Variable Speed Drive Fundamentals

the gear ratio, and accel torque by the square of the gear ratio, e.g., a 4
to 1 gear ratio will reflect 1/4 of the friction torque, and 1/16 the accel-
eration torque. If it is a simple gear box with unknown efficiency, divide
again by an efficiency factor of about 0.85; if a worm gear, divide by
0.5. If the efficiency of the gear box is known, use that figure to deter-
mine power loss through the gears.
Remember that break-away torque may be 150 to 200% of running
torque. We have to supply the worst case torque, considering friction,
and accelldecel torques, without exceeding the momentary overload
capability of the drive.
As you can see, there are some judgments that must be made to
find a balance between price, performance, and maintenance costs when
considering an application. The above guidelines should be the basis for
determining the real needs of the system. As mentioned, above, if a
drive is oversized too much, the inertia of the larger motor may be great
enough to reduce the actual response. In that case, the short-time over-
load capacity should be considered.

Estimating Torque
Sometimes it is necessary to determine the actual required torque on
an existing machine, with an installed motor, gears, etc. It may be diffi-
cult to make a mechanical determination of the required torque.
In our discussions about AC and DC motors, it was pointed out that
current is a good reflection of torque. If we can take ampere readings
during each condition of the operation, we can extrapolate an approxi-
mate torque value.
The readings should include starting current, acceleration current,
running current, and any momentary overload conditions. In other words,
we need to know worst case loading, and the duration of that load.
If an AC motor is used, note the full load amperes listed on the
motor nameplate. A 10 HP, 460v, 1750 rpm motor will probably have a
full load rating of about 13 amperes. One can assume, that under normal
running conditions, approximately 25% of the nameplate current will be
required continuously for magnetic excitation and the remainder will
produce torque. 25% of 13 amperes = 3.25 amps excitation. This leaves
9.75 “torque” amperes to do the work. The motor will develop:

(30 Ibft) I (13-3.25amps) 3.08 Ibft per toque ampere.

Basics of Applying Drives 111

If our ammeter reads 10 amps, the torque producing current is (10 -

3.25) = 6.75 amperes. We can assume that the motor is developing (6.75
torque amps x 3.08 lbft per torque amp) = 20.79 lbft of torque at 60 Hz.
20.79 Ibft x 1750 rpm I 5252 a demand of 6.9Hp.

Because there is a constant excitation current required in the AC

motor, it must always be accounted for when estimating torque. The rela-
tionship of total amperes to torque is not linear, as found with DC motors.
A 10 HP, 1750 rpm, 240 v DC motor will have a current rating of
about 38 amperes. Since this motor is also rated at 30 lbft torque, it
develops 1.26 lbft per ampere with rated field excitation.
We also know that above base speed, the AC and DC motors have
different torque characteristics. The torque of a DC motor varies
inversely with the speed in the constant horsepower range. In other
words, at double speed, the torque will be one-half and horsepower will
be constant.
The torque of an AC motor, operating on variable frequency above
base speed, varies inversely as the square of the speed at rated slip. The
AC motor produces one-quarter of rated torque at double base speed,
and rated slip. True constant horsepower at rated slip is not available.

REPLACE DC DRIVE WITH AC SYSTEM

As the reliability of the AC inverter systems has become more pre-
dictable, it has opened many opportunities to replace older DC systems
with equivalent AC drives. We will show an example in the following
pages of a procedure that can be used to make the transition, with the
confidence that it will work.

Consider Break-away Torque

The DC motor will normally handle up to 200% of its rated torque
to start a load. The AC motor, using a matching inverter on constant
torque applications, can be expected to develop about 150% starting
torque. (An oversize inverter may allow the motor to develop greater
torque-at a price.)
Running torque for the AC and DC motors will be the same up to
rated, or base speed. Above base speed, the two motors will “part com-
pany’, as the torque decline differs between the DC and AC motor. The
112 Variable Speed Drive Fundamentals

rated base speed torque of any motor can be calculated by the following
formula:
Toque = HP x 5252 I nameplate rpm

Above base speed (NP rpm) we calculate the DC torque as follows:

Toque = (rated torque x base rpm) I rpm
or
Toque = (HP x 5252) I new actual speed

Above base speed, we calculate the AC torque and speeds as fol-

lows:
Slip synchronous rpm - nameplate rpm

[Synchronous rpm at 60 Hz, will be the next speed higher than

nameplate speed, equal to 7200 divided by an even number. e.g. If
nameplate value is 1750 rpm: 7200 / 4 = 1800 synch rpm.]

New Hz = (new shaft rpm + slip) I (synch tpm) x 60Hz

[Always use synch rpm to calculate Hz]

Torque = rated torque x (60 Hz I new HZ?

New shaft rpm = (new Hz / 60) x (synch rpm) - slip

Torque by Extrapolation
An existing DC motor nameplate reads 10 HP, 240v, 38a, 1750 /
2700 rpm.
Toque = (10 Hp x 5252 ) I 1750 rpm 30 Ibft.

This is at base speed (1750 rpm), with full field, 240 volts on the
armature and drawing 38 amperes. The motor can develop this constant
torque at any speed up to 1750 rpm.

30 Ibft I38 amps = 0.79 lbft per ampere.

Every ampere in the constant torque range, up to 1750 rpm, will

produce 0.79 lbft of torque.
Basics of Applying Drives 113

For this example, we will assume that the application is operating at

2500 rpm, which is in the constant horsepower (field weakened) range.
Toque = (10HP x 5252)I2500 rpm = 21 lbft
21 lbft I 3 8 amps = 0.55 Ibft per ampere
Our ammeter reads 24 amperes.

What is the torque?

24 amps x 0.55= 13.26Ibft torque

What is the actual demand HP?

HP (13.26Ibft x 2500)I 5252 = 6.3actual demand HP

We will now try to apply a 10 Hp AC drive to this application. To

keep gearing constant, we will assume an AC motor rated 10 HP, 460v,
1750 rpm, 13 amps.
First, determine the frequency needed to produce a shaft speed of
2500 rpm at rated slip. At 60Hz the synchronous speed is 1750 + 50
rpm slip = 1800 rpm. The required rpm is 2500, so we must add the
rated slip of 50 rpm to find the new synchronous rpm. In this case we
will look for 2550 rpm, synchronous.
New Hz (2550 I 1800 ) x 60Hz = 85Hz.

What is the torque at this frequency? We already know from previ-

ous calculations that the motor will be rated at 30 lbft torque in the base
speed range.
New torque at 2500 rpm = 30 lbft x (60 / 85)2 = 14.7 lbft (49% of
rated torque), We needed 13.6 lbft, so apparently this 10 Hp AC drive
could handle the application if starting torque is adequate.
If this same DC motor were drawing 38 amperes at 2500 rpm, we
would calculate a torque requirement of 21 lbft to do the job. In this
instance, there is no way the 10 Hp AC drive can handle the load at
rated slip. We need to stay within rated slip parameters to have good
speed regulation.
Consider using a 15 Hp AC drive. The 15 Hp motor will be rated at
45 lbfl at full load. In the previous example, we determined that at 85
Hz, there will be 49% torque. 49% of 45 lbft = 22.05 lbft available.
114 Variable Speed Drive Fundamentals

50
L AC TORQUE
45
B
15 HP
F 40,
35,
DC TORQUE
T 30,-
0 25, 10 HP

20,
Q
u 15-
E 10 1 1 1 1 1 1 1 1 1 1 1 1 1 I I

Figure 9-2 AClDC Torque Comparison

Since this exceeds the 21 lbft required, the 15 Hp system would be cor-
'rect for operations at this speed and load.
If the starting torque is 200%, or 60 lbft for the DC drive, the AC
motor, with 150% of 45 lbft can provide 67.5 Ibft, and meet that
requirement.
Fig. 9-2 illustrates the torque crossover point for the 10 Hp DC
motor and 15 Hp AC motor discussed above. From these discussions,
one can see that if we have the nameplate data from the motors, and can
take reasonably accurate ampere and rpm readings, we can calculate any
conversion that might be required.
It is interesting to note that frame sizes listed on the nameplates can
tell you whether your AC motor will fit where the DC is removed. If
you divide the first two digits of any NEMA, three-digit frame size by
four, it will give you the shaft center-line to base dimension [D] in inch-
Basics of Applying Drives 115

es. e.g., Frame 224 will have an 8" center-line to base dimension. This
bit of information is useful for maintenance people who might have to
find a temporary replacement motor-just check the original nameplate
for frame size, and pick any frame equal or less for a spare, and it will
fit between the base and center-line. The shaft may or may not be the
same diameter. In some cases a 4-pole motor might be temporarily
replaced by a 6-pole motor rated at a lower Hp with equivalent torque.
e.g. [A 10 Hp,1750 rpm motor has 30 Ibft of torque, a 7.5 Hp,1150
rpm motor has 34.25 lbft of torque]

In summary, there are other factors that must also be taken into con-
sideration, such as regenerative loads, etc. that might not be compatible
with a standard AC Drive control package. In some cases, such as hoist-
ing applications, a special regenerative section, or vector-control system
would be required to match the energy absorption capability of the DC
drive. See Chapter 13 for a case history of an actual project.