Yaskawa Electric America

The Basics of AC Drive Applications

PP.AFD.01.AfdDriveApplBasics 1 of 123

6/6/2002

Basic Definitions

Definitions

To get a good understanding of applications, it is advantageous to understand: Power - the rate of doing work Torque - twisting power Load Torque - torque required to perform an application Motor Torque - torque available from the prime mover

Power and Torque

Power is the rate of doing work. Power is a product of torque and speed.

P =T x n
Where: T - torque n - speed

Power and Torque

P =T x n
High

P T n

High

P T n

Med

Med

Low

Low

Power increases if torque increases

Power and Torque

P =T x n
High

P T n

High

P T n

Med

Med

Low

Low

Power increases if speed increases

Power and Torque

Power increases as speed increases

125%

High

P T n
100%

X
Torque Power

Med

75%

50%

Low
25%

Power and speed are low and torque is constant.

0%

X
0% 50% 100%

Speed (%)

Power and Torque

Power increases as speed increases

125%

High

P T n
100%

X
Torque Power

Med

75%

50%

Low
25%

Power increases proportionally with speed.

X
0% 50% 100%

0%

Speed (%)

Power and Torque

Power increases as speed increases

125%

High

P T n
100%

X
Torque Power

Med

75%

50%

Low
25%

Power increases proportionally with speed.

0% 0% 50% 100%

Speed (%)

Power and Torque

Power increases as speed increases

125%

High

P T n
100%

X X
Torque Power

Med

75%

50%

Low
25%

Power increases proportionally with speed.

0% 0% 50% 100%

Speed (%)

Power and Torque

Power increases as speed increases

125%

High

P T n
100%

X X
Torque Power

Med

75%

50%

Low
25%

Power increases proportionally with speed.

0% 0% 50% 100%

Speed (%)

Types of Loads

Types of Loads

Loads can be grouped into four categories:

Variable Torque Loads

Load changes with speed

Constant Torque Loads

Load does not change with speed

Constant Horsepower Loads

Load considerations above motor base speed

Impact Loads

Load is intermittent, not connected to speed

Variable Torque Loads

With a variable torque load, torque loading is a function of the speed. The torque will change with the square of the speed and the horsepower will change with the cube of the speed.
This characteristic is typical of centrifugal type fans and pumps.

100%

80%

60%

Torque
Horsepower

40%

20%

0% 0% 50% 100%

Speed (%)
8

Variable Torque Loads

With a variable torque load, torque loading is a function of the speed. The torque will change with the square of the speed and the horsepower will change with the cube of the speed.
This characteristic is typical of centrifugal type fans and pumps.

100%

80%

60%

Torque
Horsepower

40%

20%

0% 0% 50% 100%

Speed (%)

Variable Torque Loads

These variable torque characteristics are a result of the affinity laws of centrifugal machinery.

The ratio of torque 1 to torque 2 is equal to the ratio of speed 1 squared to speed 2 squared.
The ratio of horsepower 1 to horsepower 2 is equal to the ratio of speed 1 cubed to speed 2 cubed.

T1 T2

(n1 )2 (n2 )2

(n1 )3 HP1 = HP2 (n2 )3

9

Variable Torque Loads

The basic affinity laws can be converted for use with centrifugal fans and pumps.

Flow is directly proportional to speed.

Pressure is directly proportional to the square of the speed.

F1 F2
P1 P2

n1 n2 (n1 )2 (n2 )2

Horsepower is directly proportional to the cube of the speed.

(n1 )3 HP1 = HP2 (n2 )3

10

Variable Torque Loads

Not all fans and pumps are variable torque loads:

Fans are grouped in 2 major categories: Fans and Blowers (variable torque)

Compressors (constant torque)

Pumps are grouped in 2 major categories: Centrifugal (variable torque) Positive Displacement (constant torque)

11

Fan Loads
Fan/Blowers
Variable Torque Centrifugal Radial Blade Forward Curve Backward Incline Axial Propeller Tubeaxial Vaneaxial

Compressors
Constant Torque
Reciprocating Piston Diaphragm Rotary Rotary Lobe Screw

12

Constant Torque Loads

With a constant torque load, torque loading is not a function of the speed. As the speed changes the load torque remains constant. Horsepower will change with speed.
This characteristic is typical of positive displacement pumps and conveyors.

125%

100%

75%

Torque Horsepower

50%

25%

0% 0% 50% 100%

Speed (%)
13

Constant Torque Loads

With a constant torque load, torque loading is not a function of the speed. As the speed changes the load torque remains constant. Horsepower will change with speed.
This characteristic is typical of positive displacement pumps and conveyors.

125%

100%

75%

Torque Horsepower

50%

25%

0% 0% 50% 100%

Speed (%)

Constant Torque Loads

The torque and horsepower formulas for rotating machinery can better illustrate the graph on the previous slide. The horsepower changes linearly with speed when the torque stays constant.

HP =

T x rpm 5250

The torque remains constant when the horsepower changes linearly with speed.

HP x 5250 T = rpm
Where: Torque is represented in ft-lbs
14

Constant Horsepower Loads

With a constant horsepower load, 125% torque loading is a function of the speed in the constant 100% horsepower range. As the speed changes, the 75% load torque will decrease at a rate inversely proportional 50% with speed (1/n). 25% Horsepower generally remains constant. 0% This characteristic is typical of machine tool spindle drives.
0% 50%

base speed

Torque Horsepower

100%

150%

200%

Speed (%)
15

Constant Horsepower Loads

With a constant horsepower load, torque loading is a 125% function of the speed in the constant 100% horsepower range. As the speed changes, the 75% load torque will decrease at a rate inversely proportional 50% with speed (1/n). Horsepower 25% generally remains constant. 0% This characteristic is typical of machine tool spindle drives.
0% 50%

base speed

Torque Horsepower

100%

150%

200%

Speed (%)

Constant Horsepower Loads

What happens to torque in the constant horsepower area can be found below.
Example: A 5 HP, 1750 rpm, 60Hz motor will be run to 3500 rpm (120Hz). HP x 5250 = T rpm

100% base speed and below

A B

above 100% base speed

D

0.5 HP x 5250 = 15 ft-lbs 175 rpm

5 HP x 5250 = 12 ft-lbs 2187 rpm 5 HP x 5250 = 10 ft-lbs 2625 rpm 5 HP x 5250 = 8.6 ft-lbs 3062 rpm 5 HP x 5250 = 7.5 ft-lbs 3500 rpm

2.5 HP x 5250 = 15 ft-lbs 875 rpm 5 HP x 5250 C = 15 ft-lbs 1750 rpm

E F

16

Constant Horsepower Loads

Points A through G can be found on the speed torque curve below.

16
A

15
B
C

Torque (ft-lbs)

14 12
E

10
F

10

8 6 4 2 0
1750

Horsepower

Torque Horsepower

3500 0 17

Speed (rpm)

Impact Loads

125%

1500 1200 900 600 300 0

100% 75% 50% 25% 0%

This type of load characteristic is typical of a punch press or any equipment that uses a flywheel.

Time
18

Motor Speed (rpm)

Torque (%)

Impact loads have intermittent torque requirements, which are not a function of speed.

MotorTorque
175% 1800 150%
Load Torque Motor Speed

Impact Loads

Torque (%)

125% 100% 75% 50% 25% 0%

1500 1200 900 600 300 0

This type of load characteristic is typical of a punch press or any equipment that uses a flywheel.

Time

Motor Speed (rpm)

Impact loads have intermittent torque requirements, which are not a function of speed.

MotorTorque Load Torque

175% 1800 150%

Motor Speed

Calculation of Torque

Calculations

The next section will explain how to calculate the following:

Acceleration Torque Deceleration Torque Torque and Speed Through a Gearbox

19

Calculating Acceleration Torque

Acceleration torque is the difference between the available motor torque and the torque required to drive the load.
Breakdown Torque (200-250%) Pull Up Torque (125%) (200%)

TORQUE

(200%)

(150%)
Torque available for accel and decel. Torque required to drive the load.

Motor Full Load Torque (100%)

(100%)

SPEED

20

Calculating Acceleration Torque

To calculate the acceleration torque (TA), the following items must be known:

The total inertia in lb-ft2. (WK2)

The change in motor speed. (rpm)

WK2 x rpm TA = 308 x ta

Where: Torque is represented in ft-lbs

The required acceleration time in seconds. (ta)

Total inertia includes the inertia of the load, inertia of the gearbox and the inertia of the motors rotor.
21

Calculating Acceleration Torque

A typical example of calculating acceleration torque:

Example: A 5HP, 1750 rpm, 60Hz motor and a 5HP inverter are used to run a conveyor. The total inertia is 10 lb-ft2. The desired acceleration time, between 0 and 1750 rpm, is 15 seconds.

TA =

WK2 x rpm

308 x ta

10 lb-ft2 x 1750 rpm 3.8 ft-lbs = 308 x 15 seconds

The above information indicates the amount of acceleration torque required, but does not tell us if the 5HP motor and inverter are capable of achieving the specified performance.

22

Calculating Acceleration Torque

Determine the motor rated torque and the torque required to drive the load.
Example: A 5HP, 1750 rpm, 60Hz motor and a 5HP inverter are used to run a conveyor. The total inertia is 10 lb-ft2. The desired acceleration time, between 0 and 1750 rpm, is 15 seconds. 80% of the motor rated torque is required to drive the load. Motor Rated Torque

HP x 5250 Tr = rpm

Load Torque

5HP x 5250 15 ft-lbs = 1750

Note-In this example the motor rated current and the inverter rated current are equal.

12 ft-lbs
torque required to move the load at constant speed 12 ft-lbs is 80% of 15 ft-lbs 23

Calculating Acceleration Torque

The maximum available motor torque will be determined by the inverter ampacity overload rating. Torque is proportional to current through a major portion of the speed range. A typical inverter overload rating is 150% for 1 minute.
(200%) Maximum available motor torque. (30 ft-lbs)

(22.5 ft-lbs)

Maximum Available Motor Torque

15 ft-lbs x 150% = 22.5 ft-lbs

Note-In this example the motor rated current and the inverter rated current are equal.

(100%)

(15 ft-lbs) (12 ft-lbs)

Torque required to drive the load.

24

Speed - Torque Curve

(300%) (600%)

Slip

TORQUE

CURRENT
(300%)
Breakdown Torque (200-250%) Pull Up Torque (125%)

(200%)
Locked Rotor Torque (150%) Full Load Torque (100%)

No Load Current (30%)

SPEED

Rated Speed Synch Speed

25

Speed - Torque Curve

(300%) (600%)

Slip

TORQUE

CURRENT
(300%)
Breakdown Torque (200-250%) Pull Up Torque (125%)

(200%)
Locked Rotor Torque (150%) Full Load Torque (100%)

Current Torque No Load Current (30%)

SPEED

Rated Speed Synch Speed

Calculating Acceleration Torque

The torque available for acceleration is the difference between the available motor torque and the torque required to drive the load.
Torque Available for Acceleration

22.5 ft-lbs - 12 ft-lbs = 10.5 ft-lbs

(200%) Maximum available motor torque. (100%) Torque required to drive the load. (30 ft-lbs)

(22.5 ft-lbs)

(15 ft-lbs) (12 ft-lbs)

Torque available for acceleration. (10.5 ft-lbs)

26

Calculating Acceleration Torque

Determine if the 5HP motor is capable of achieving the specified performance.

Example: A 5HP, 1750 rpm, 60Hz motor and a 5HP inverter are used to run a conveyor. The total inertia is 10 lb-ft2. The desired acceleration time, between 0 and 1750 rpm, is 15 seconds. 80% of the motors rated torque is required to drive the load.
Motor rated torque = 15 ft-lbs Load torque = 12 ft-lbs Maximum available motor torque = 22.5 ft-lbs

Tr =

HP x 5250 rpm

(Tr x 150%) (Max. available - load torque) TA = WK2 x rpm 308 x ta

27

Torque available for acceleration = 10.5 ft-lbs

Torque required for acceleration = 3.8 ft-lbs

Torque available for acceleration > Torque required for acceleration

Time to do an exercise

Calculating Acceleration Torque

Using the formulas below, determine if the performance specification can be achieved for the the following application.

Example: A 10HP, 1750 rpm, 60Hz motor and a 10HP inverter are used to run a boring machine. The total inertia is 19 lb-ft2. The desired acceleration time, between 0 and 1750 rpm, is 4 seconds. 90% of the motor rated torque is required to drive the load.
Motor rated torque = _____ ft-lbs Load torque = _____ ft-lbs Maximum available motor torque = _____ ft-lbs Torque available for acceleration = _____ ft-lbs Torque required for acceleration = _____ ft-lbs = (Tr x 150%) = (Max. available - load torque) Tr = HP x 5250 rpm

TA =

WK2 x rpm 308 x ta

Torque available for acceleration ____ Torque required for acceleration

Note-In this example the motor rated current and the inverter rated current are equal. 28

Calculating Acceleration Torque

Using the formulas below, determine if the performance specification can be achieved for the the following application.

Example: A 10HP, 1750 rpm, 60Hz motor and a 10HP inverter are used to run a boring machine. The total inertia is 19 lb-ft2. The desired acceleration time, between 0 and 1750 rpm, is 4 seconds. 90% of the motor rated torque is required to drive the load.
Motor rated torque = _____ ft-lbs Load torque = _____ ft-lbs

30

Tr =

HP x 5250 rpm

27

45 Torque available for acceleration = _____ 18 ft-lbs

Torque required for acceleration = _____ ft-lbs

Maximum available motor torque = _____ ft-lbs

= (Tr x 150%) = (Max. available - load torque)

27

TA =

WK2 x rpm 308 x ta

Torque available for acceleration ____ < Torque required for acceleration

The specified performance is not achieved!

Now what do we do?

Calculating Acceleration Torque

When more acceleration torque is required than is available, the inverter current rating may be increased to handle the increase in current.
(200%) Maximum available motor torque. (60 ft.lbs) Torque required for acceleration. (27 ft.lbs) Torque available for acceleration. (18 ft.lbs)

(45 ft.lbs)

(100%)

(30 ft.lbs) (27 ft.lbs)

Torque required to drive the load.

Torque available for acceleration

Torque required for acceleration

18 ft.lbs

27 ft.lbs
29

Calculating Acceleration Torque

Use the following formula to determine the necessary current rating increase to achieve the required acceleration torque.

Inverter Output Rating Increase

Torque Required for Acceleration + Load Torque

Torque Available for Acceleration + Load Torque

120%

27 ft-lbs + 27 ft-lbs

18 ft-lbs + 27 ft-lbs

Choose an inverter with a continuos output current of 120% of the motor full load current.
30

Calculating Deceleration Torque

Deceleration torque is the sum of the windage and friction losses and either the motor breakdown torque or the inverter braking torque (which ever is smaller).
Breakdown Torque
(approx 250% )

(approx 10%)
Motor

Braking Torque
(approx 10-15% )

Smallest

Windage & Friction Losses

Inverter

Available Decel Torque

31

Calculating Deceleration Torque

To calculate the deceleration torque (TD) the following items must be known:

The total inertia in lb-ft2. (WK2)

WK2 x rpm TD = 308 x td

Where: Torque is represented in ft-lbs

The change in motor speed. (rpm)

The required deceleration time in seconds. (td)

Total inertia includes the inertia of the load, inertia of the gearbox and the inertia of the motors rotor.

32

Calculating Deceleration Torque

When running a motor with an inverter in the motoring mode, the power flows from the inverter to the motor.

(+)

L1 L2 L3

M
1FU

(-)

33

Calculating Deceleration Torque

In the regenerative mode, the power flows from the motor to the inverter.

(+)

L1 L2 L3

M
1FU

(-)

34

Calculating Deceleration Torque

When in the regenerative mode, power cannot go through the input diodes, back to the ac power line. This may cause the DC bus voltage inside the inverter to climb to excessive levels. If the DC bus voltage goes too high, the inverter will protect itself by tripping on an overvoltage fault.
(+)

L1 L2 L3

M
1FU

(-)

35

Calculating Deceleration Torque

Since there is nowhere to dissipate the regenerative energy, the amount of deceleration or braking torque available from the motor and inverter combination is limited. Braking torque for a motor and inverter combination is typically in the range of 10 - 15%.
(+)

L1 L2 L3

M
1FU

(-)

36

Calculating Deceleration Torque

Energy to be dissipated by braking resistors Mechanical energy in load machine

Inverter Losses IGBT Switching

Motor Losses I2 R Core

5% large inverters/motors
37

10-15% small inverters/motors

Calculating Deceleration Torque

A typical example of calculating deceleration torque:

Example: A 5HP, 1750 rpm, 60Hz motor and a 5HP inverter are used to run a conveyor. The total inertia is 10 lb-ft2. The desired deceleration time, between 1750 and 0 rpm is 20 seconds

TD =

WK2 x rpm

308 x td

10 lb-ft2 x 1750 rpm 2.8 ft.lbs = 308 x 20 seconds

The above information indicates the amount of deceleration torque required, but does not tell us if the 5HP motor and inverter are capable of achieving the specified performance.

38

Calculating Deceleration Torque

Determine the windage and friction losses of the application. If this data is not known assume 0.
Example: A 5HP, 1750 rpm, 60Hz motor and a 5HP inverter are used to run a conveyor. The total inertia is 10 lb-ft2. The desired deceleration time, between 1750 and 0 rpm is 20 seconds Windage and friction losses are 7% of the motor rated torque.

HP x 5250 Tr = rpm
L = Tr x L%
Where L% - Percentage of windage and friction losses L - Windage and friction losses in ft-lbs

Motor Rated Torque

Losses

5HP x 5250 15 ft-lbs = 1750

1.05 ft-lbs
39

Calculating Deceleration Torque

Friction losses can be put into two categories: Mechanical Friction

Bearing Friction - friction between front and rear rotor shaft bearings

Air Friction

Rotor Fan Windage - friction of air on rotor fan blade surface External Fan Windage - friction of air on external fan blade surface

Note: Windage and friction losses are basically constant throughout the speed range.
40

Calculating Deceleration Torque

Determine the amount of braking torque required, by subtracting the windage and friction losses from deceleration torque required .
Example: A 5HP, 1750 rpm, 60Hz motor and a 5HP inverter are used to run a conveyor. The total inertia is 10 lb-ft2. The desired deceleration time, between 1750 and 0 rpm, is 20 seconds. Windage and friction losses are 7% of the motor rated torque.

TB = TD - L
Where TB - Braking torque required in ft-lbs

1.75 ft-lbs = 2.8 ft-lbs - 1.05 ft-lbs

41

Calculating Deceleration Torque

Determine the percentage of braking torque required.

Example: A 5HP, 1750 rpm, 60Hz motor and a 5HP inverter are used to run a conveyor. The total inertia is 10 lb-ft2. The desired deceleration time, between 1750 and 0 rpm, is 20 seconds. Windage and friction losses are 7% of the motor rated torque.

TB % =
Where -

TB Tr

TB % - Percentage of braking torque

1.75 ft-lbs 11.6% = 15 ft-lbs

Torque required for deceleration < 15%

The specified performance is achieved!

42

Time to do an exercise

Calculating Deceleration Torque

Using the formulas below, determine if the performance specification can be achieved for the following application.

Example: A 10HP, 1750 rpm, 60Hz motor and 10HP inverter are used to run a lathe. The total inertia is 15 lb-ft2. The desired deceleration time, from 1750 to 0 rpm, is 2 seconds. Windage and friction losses are 5%.
Torque required for deceleration = _____ ft-lbs Motor rated torque = _____ ft-lbs TD = Tr = WK2 x rpm 308 x td HP x 5250 rpm

Windage /Friction losses= _____ ft-lbs

Braking Torque = _____ ft-lbs Braking Torque = _____ %

L = Tr x L% TB = TD - L TB % = TB Tr
43

Torque required for acceleration ______ 15%

Calculating Deceleration Torque

Using the formulas below, determine if the performance specification can be achieved for the following application.

Example: A 10HP, 1750 rpm, 60Hz motor and 10HP inverter are used to run a lathe. The total inertia is 15 lb-ft2. The desired deceleration time, from 1750 to 0 rpm, is 2 seconds. Windage and friction losses are 5%.
Torque required for deceleration = _____ ft-lbs Motor rated torque = _____ ft-lbs

43

TD = Tr =

WK2 x rpm 308 x td HP x 5250 rpm

30

Windage /Friction losses= _____ ft-lbs

Braking Torque = _____ ft-lbs Braking Torque = _____ %

1.5

L = Tr x L% TB = TD - L TB % = TB Tr

41.5

138

Torque required for acceleration ______ 15% The specified performance is not achieved!

>

Now what do we do?

Types of Braking

If the braking torque required is more than 15%, one of 3 braking methods must be used to achieve the specified performance.

DC Injection Braking Dynamic Braking Regenerative Braking

44

DC Injection Braking

DC injection braking utilizes the DC current from the DC bus of the inverter to produce a stationary magnetic field in the motor. The rotor passes through the stationary field and a braking torque is produced.
Braking Torque - approx 50% Duty Cycle - Typically 3-5% (motor dependent)

S
45

Dynamic Braking

Dynamic braking is a process in which regenerative energy from the load is dissipated as heat across a bank of resistors.

(+)

L1 L2 L3

M
1FU

(-)

Resistor BTR HEAT

Braking Torque - See chart on next page Duty Cycle - See chart on next page
46

Dynamic Braking

47

Regenerative Braking

Regenerative braking requires the use of a DC to AC converter to direct the regenerative energy from the load, back onto the AC power line.
(+) (+)

L1 L2 L3

Regenerative Converter
1FU

(-)

(-)

Braking Torque - 100% continuos, 150% peak Duty Cycle - Typically 100%
48

Gearboxes

A gearbox is used to transmit power from a motor to the driven machine. It can change the amount of torque and speed delivered to the load.

Input

Output Gearbox

Motor

49

Gearboxes

To determine the output torque of a gearbox, utilize the formula below:

Input

Output Gearbox

Motor

TO = TI x RG x EG

Where: TO = Torque on the output shaft in ft-lbs

TI = Torque on the input shaft in ft-lbs

RG = The ratio of the gearbox EG = Efficiency of the gearbox
50

Gearboxes

A typical example of calculating the torque available from the output of a gearbox can be found below.
Example: A 5HP, 1750 rpm, 60Hz motor is connected to a 30:1 gearbox. The gearbox efficiency is 90%. What is the expected torque on the output shaft of the gearbox ? HP x 5250 Tr = rpm

TO = TI x RG x EG

5HP x 5250 15 ft.lbs = 1750 rpm 405 ft-lbs= 15 x 30 x 0.90

The expected torque on the output shaft of the gearbox is 405 ft-lbs
51

Gearboxes

To determine the output speed of a gearbox, utilize the formula below:

Input

Output Gearbox

Motor

nO =

nI RG

Where: nO = Speed on the output shaft in rpm

nI = Speed on the input shaft in rpm

RG = The ratio of the gearbox
52

Gearboxes

A typical example of calculating the speed available from the output of a gearbox can be found below.
Example: A 5HP, 1750 rpm, 60Hz motor is connected to a 30:1 gearbox. The gearbox efficiency is 90%. What is the expected speed on the output shaft of the gearbox ? nI RG

nO =

58.3 rpm =

1750
30
The expected speed on the output shaft of the gearbox is 58.3 rpm.
53

Time to do an exercise

Gearboxes

Using the formulas below, determine if the performance specification can be achieved for the the following application.

Example: A 5HP, 1750 rpm, 60Hz motor and 5HP inverter are used to run a conveyor. The speed range of the motor/inverter is 45 - 1750 rpm. 200 ft-lbs is required to adequately run the load. The customer wants to be able to adjust the speed of the gearbox output shaft between 50 and 60 rpm. The gearbox is rated at 20:1 and is 90% efficient. HP x 5250 = Tr Motor rated torque = _____ ft-lbs rpm
Gearbox Output Torque = _____ ft-lbs

TO = TI x RG x EG

Gearbox Output Speed Range = _____ rpm

SO =

SI
RG
54

Can the application be performed ?______

Gearboxes

Using the formulas below, determine if the performance specification can be achieved for the the following application.

Example: A 5HP, 1750 rpm, 60Hz motor and 5HP inverter are used to run a conveyor. The speed range of the motor/inverter is 45 - 1750 rpm. 200 ft-lbs is required to adequately run the load. The customer wants to be able to adjust the speed of the gearbox output shaft between 50 and 60 rpm. The gearbox is rated at 20:1 and is 90% efficient. HP x 5250 = Tr Motor rated torque = _____ 15 ft-lbs rpm
Gearbox output torque = _____ ft-lbs

270

TO = TI x RG x EG

Gearbox Output Speed Range = _________ rpm

2-88

SO =

SI
RG

YES Can the application be performed ? ______

Dynamic Braking

Dynamic Braking

In most applications a standard dynamic braking package will achieve the desired performance. In some applications the standard dynamic braking package will not work. In these cases a special dynamic braking package must be designed to achieve the desired performance. The next section will explain the following:

How to determine if a standard dynamic braking package will achieve the desired performance. How to determine the specifications of a non-standard dynamic braking package.
55

Braking Packages

A braking package consists of a braking transistor unit and a resistor box.

A standard braking package has already been designed by the inverter drive manufacturer to produce a specific amount of braking torque at a specific duty cycle. A non-standard braking package has been designed to work with a specific application. The ohmic and wattage values of the resistors and the number of braking transistor units vary with application requirements.
Standard
Inverter
Braking Transistor

Non-standard
50 9kW Inverter
Braking Transistor

12 14.5kW 12 14.5kW

Braking Transistor

56

Standard Braking Package

To determine if a standard braking package can be used, follow the steps listed below: Determine the amount of braking torque required.

Determine if the standard braking package can produce more braking torque than is required.
Determine the duty cycle required.

Determine if the standard braking package duty cycle is higher than the duty cycle required.

57

Standard Braking Package

Example: A 20HP, 1750 rpm, 230Vac, 60Hz motor and 20HP inverter are used to run a conveyor. A 10:1 gearbox rated 90% efficient is connected between the motor and the load. The load inertia on the output of the gearbox is 3600 lb-ft2, the gearbox inertia is 2 lb-ft2 and the rotor inertia is 2 lb-ft2. The desired deceleration time, between 175 and 0 gearbox output rpm, is 5 seconds. Windage and friction losses are 7% of the motor rated torque. The conveyor will be started and stopped once each 10 minutes, with 1 minute of off time. Can the desired performance be achieved with the standard dynamic braking package?
Input Motor Output

Gearbox

58

Determine Braking Torque

Determine the amount of torque and speed on the input and output of the gearbox.

Example: A 20HP, 1750 rpm, 230Vac, 60Hz motor and 20HP inverter are used to run a conveyor. A 10:1 gear box rated 90% efficient is connected between the motor and the load.

Tr = TO

HP x 5250 rpm = TI x RG x EG SI RG

SO =
Output

60 ft-lbs 1750 rpm

Motor

Input Gearbox

540 ft-lbs 175 rpm

10:1 90%
59

Determine Braking Torque

Determine the amount of inertia reflected back to the motor.

Example: The load inertia is 3600 lb-ft2. Gearbox and rotor inertia are 2 lb-ft2 respectively. WK2O The desired deceleration time is 5 WK2I = seconds between 1750 and 0 motor rpm. RG 2 Windage and friction losses are 7% of the motor rated torque.

36 + 2 + 2 = 40 lb-ft2 Input
Motor Gearbox

Output

Input 60 ft-lbs 1750 rpm

3600 lb-ft2

Output 540 ft-lbs 175 rpm

60

Determine Braking Torque

Determine the amount of braking torque required to achieve the desired performance. WK2I x rpm

Example: The load inertia is 3600 lb-ft2. Gearbox and rotor inertia are 2 lb-ft2 respectively. The desired deceleration time is 5 seconds between 1750 and 0 motor rpm. Windage and friction losses are 7% of the motor rated torque.

TD =

308 x td

L = Tr x L% TB = TD - L TB % = TB Tr
Output 540 ft-lbs 175 rpm 3600-lb-ft2
61

TB = 41.3 ft-lbs Input TB% = 69%

Input
Motor Gearbox

Output

60 ft-lbs 1750 rpm 40-lb-ft2

Determine Braking Torque

Compare the amount of braking torque required, to the amount of braking torque available from the standard braking package. Required Example: Refer to page 37 for a complete
list of the standard braking package specifications.

TB% = 69%

HP 20

kW 15

Braking Torque 120%

The specified torque performance is achieved!

62

Determine Duty Cycle

Determine the duty cycle of the braking circuit.

Example: The conveyor will be started and stopped once each 10 minutes, with 1 minute of off time.

Where : D = td D - Duty Cycle t - Total cycle time td - Decel time

t
5s 11m

0.75% =

5s 660s
63

Determine Duty Cycle

Compare the duty cycle required to the duty cycle of the standard braking package. Refer to page 37 for standard braking package duty cycle specification.

Example: The conveyor will be started and stopped once each 10 minutes, with 1 minute of off time.

Required D = 0.75%

HP 20

kW

Braking Torque 120%

Duty Cycle
10%

15

The specified performance is achieved!

64

Non-standard Braking Package

Example: A 20HP, 1750 rpm, 230Vac, 60Hz motor and 20HP inverter are used to run an automated lathe. A 2:1 gearbox rated 90% efficient is connected between the motor and the load. The load inertia on the output shaft of the gearbox is 234 lb-ft2, the gearbox inertia is 2 lb-ft2 and the rotor inertia is 2 lb-ft2. The desired deceleration time, between 875 and 0 gearbox output rpm, is 4 seconds. Windage and friction losses are 3% of the motor rated torque. The lathe will be started and stopped once each 10 seconds, with 2 seconds of off time. Can the desired performance be achieved with the standard dynamic braking package? Output Input
Motor

Gearbox

65

Non-standard Braking Package

Determine the braking torque and duty cycle required to achieve the desired performance.
Motor rated torque = _____ ft-lbs

60

Tr =

HP x 5250 rpm

Output torque = _____ ft-lbs

108

TO = TI x RG x EG SO = SI RG WK2O RG 2

Output speed = _______ rpm

875

Total inertia = _______ lb-ft2

62.5

WK2I =

Torque required for deceleration = ________ ft-lbs

88.7

TD =

WK2I x rpm 308 x td

66

Non-standard Braking Package

Determine the braking torque and duty cycle required to achieve the desired performance.
Windage /Friction losses= _____ ft-lbs Braking Torque = ________ ft-lbs

1.8

L = Tr x L% TB = TD - L TB % = D = TB Tr td t

86.9

144 % Braking Torque = ________

Required Duty Cycle = ________ %

33

Standard
HP 20 kW 15 Braking Torque 120% Duty Cycle 10%

Required 144% Torque 33% Duty Cycle

67

Non-standard Braking Package

Use the following formula to determine the ohmic value of the braking resistor.

VDC2 RB = 1.027 x (TB x 0.14) x rpm

Where: VDC2 - Braking transistor turn on voltage squared TB - Braking torque in ft-lbs 0.14 - ft-lbs to kg-m conversion

1.027 - Mechanical to electrical conversion factor

385 2 6.8 = 1.027 x ( 12.2 ) x 1750

The ohmic value required to produce 144% braking torque is 6.8

68

Non-standard Braking Package

Use the following formulas to determine the wattage value of the braking resistor. Pave = 1.027 x (TB x 0.14) x rpm x 10 -3 WB = Pave m

11kW = 1.027 x ( 12.2 ) x 875 x 10 -3 11kW 29kW = 0.38

Refer to the next page for a typical resistor m value.

The wattage value required to withstand a 33% duty cycle, at 144% braking torque is 29kW.
69

Non-standard Braking Package

m value for an application with repeating deceleration
10 1% DUTY 10% CYCLE 33%

m value for an application with non-repeating deceleration

1s DECEL TIME 10s 100s

100%

3
20 m 1 10 m

0.5 0.38

x
2 1
70

0.1

These charts are for example only, actual resistor data must be obtained from the resistor manufacturer.

Non-standard Braking Package

Use the following formula to determine the number of braking transistor units required based on the current requirements.

IB = N =

VDC RB IB IP

385 57A = 6.8 57A 1.425 = 40A

Where : IB - braking current IP - balancing factor

N - number of braking transistor units required VDC - Braking transistor turn on voltage

The braking current is 57A and the number of braking transistor units is 1.425, or 2. The number of braking transistor units calculated must be verified with the overcurrent protection curve.
71

Non-standard Braking Package

The proposed braking package will be assembled as shown below. Each braking unit will carry 28.5 amps.

Inverter

P
Braking Transistor

12 14.5kW 28.5 Amps 12 28.5 Amps 14.5kW

N
Braking Transistor

The following information will be used to determine if this configuration exceeds the braking transistor unit overcurrent protection curve.

Braking Current ( IB ) divided by the proposed number of braking units ( N ) Deceleration Time ( td )

Duty Cycle ( D )

72

Non-standard Braking Package

The specifications for the application do not exceed the braking transistor unit overcurrent protection curve.
5%

IB N = 28.5A Decel time = 4 sec 400 Duty Cycle = 33% Deceleration Time ( td )
10% 20%

100

5% Duty Cycle 10% Duty Cycle 20% Duty Cycle 40% Duty Cycle 60% Duty Cycle

40

10

X
40% 60%

10

20

30 IB N

40

50

73

Non-standard Braking Package

To achieve the desired performance the braking package will be assembled as shown below.

Inverter

P N

Braking Transistor

12 14.5kW 12 14.5kW

Braking Transistor

Never connect a braking resistor with a lower ohmic value than specified by the manufacturer. When using more than one braking transistor some manufacturers have a master - slave configuration so both braking transistors will work as one.

74

100% Duty Cycle

Use the following formula to determine the number of braking transistor units required for 100% duty cycle.

IB =

VDC RB

IB - Y + ( Y x 0.8 ) N = Y

385 57 A = 6.8

Where : Y - braking transistor unit RMS current rating 0.8 - balancing factor N - number of braking transistor units required VDC - Braking transistor turn on voltage

57 - 15 + ( 15 x 0.8 ) 3.6 = 15
The formula above must be used to determine the number of braking transistor units when 100% duty cycle is required. If a 100% duty cycle was required for this example, 4 braking transistor units would be required.
75

The effects of the speed range on motor heating

Speed Control Range and Motor Heating

There are 4 basic categories of speed ranges for a general purpose induction motor.

More than 100% (above base speed) 50 - 100% (2:1) 16 - 50% (6:1) Less than 16% (more than 6:1)

76

Overall Consideration

Whenever running a general purpose induction motor on an inverter, the motor must be derated as shown below.

It is required to derate an induction motor with a 1.0 service factor to 85% of its rated power output. The derating can be eliminated if a motor with a 1.15 service factor is used, and the load does not exceed the 1.0 service factor rating.

85%
1.15 SF but only use 1.0 SF
77

Overall Consideration

There are 2 main reasons for the derating;

voltage

The rating of an induction motor is based on a sinusoidal voltage and current waveform. The output of an inverter is not a pure sine wave and includes extra harmonic currents. More heat will be generated in the motor, with no additional capability to dissipate the heat. When the motor speed is reduced the motors cooling fan losses its capacity to move air inside and/or across the surface of the motor. This reduction in cooling leads to a higher running temperature.

current

78

More Than 100% (above base speed)

Variable Torque Load

Constant HP Load

Running a variable torque application above base speed is normally not recommended. Typically the maximum speed of the fan or pump matches the required flow when the motor is running at rated speed. Increasing the pump speed will increase the flow as well as the load, and could possibly lead to an overload condition.

Typically this situation does not cause a problem. The motor torque drops off reducing the load and the motors cooling fan continues to cool the motor. Consult the motor manufacturer for the motors mechanical maximum speed. Only the overall consideration should be adhered to in this situation.

79

50 - 100% (2:1)
Overall Consideration

Derate a motor with a 1.0 service factor to 85% of its rated power.

The derating can be eliminated if a motor with a 1.15 service factor is used, and the load does not exceed the 1.0 service factor rating.

De-Rating

When running an induction motor on an inverter inside the 2:1 speed range, only the overall considerations previously discussed should be adhered to.

100/85 %

30Hz 50%

45Hz 75% Motor Speed 1.0 SF 1.15 SF

60Hz 100%

80

 16 - 50% (6:1)
Variable Torque Load

Constant Torque Load

Typically no special derating other than the overall consideration is required when running a variable torque load in the 6:1 speed range. In some cases, such as a centrifugal pump, the load takes on the appearance of a constant torque load at low speeds. If this is the case, the constant torque specifications should be followed.

Motor derating when running a constant torque application in the 6:1 range is shown below.
De-Rating

100/85 %

87/72 % De-Rating 75/60 % 10Hz 16% 1.0 SF 1.15 SF

20Hz 33% Motor Speed

30Hz 50% 81

Less than 16% (more than 6:1)

Constant Torque Load

When running an induction motor with more than a 6:1 speed range, additional cooling considerations are required. Separate motor cooling must be provided for the motor. Typically a separately powered blower attached to the motor is used to provide airflow over the surface of the motor. Since the blower is separately powered, there is no reduction in motor cooling at low motor speeds which is inherent to a TEFC type motor.
82

Motor Overload Types

Motor Overloads

There are 6 basic categories of motor overload protection devices.

Melting Alloy type Magnetic Bi-Metallic Bi-Metallic Thermo Disc Thermistor Electronic Thermal Overload
83

Melting Alloy Type

Melting alloy type overload relays are the most common type overload used in industry today. Motor current flows through an alloy heater coil and produces a proportional amount of heat. At a specific temperature (thus a specific current) the alloy changes from a solid to a liquid. The melting alloy causes a mechanism to release and open a set of contacts. A cool off time is required for the alloy to return to a solid.

Reset Button

L1

Spring

Heater Coil

T1
84

Melting Alloy Type

Melting alloy type overload relays are the most common type overload used in industry today. Motor current flows through an alloy heater coil and produces a proportional amount of heat. At a specific temperature (thus a specific current) the alloy changes from a solid to a liquid. The melting alloy causes a mechanism to release and open a set of contacts. A cool off time is required for the alloy to return to a solid.
Reset Button

L1

Spring

Heater Coil

T1

Melting Alloy Type

10.00 9.00 8.00 7.00 Trip/minutes Class 20 Trip/minutes Class 10

Melting alloy type overload relays are normally identified by class designations Class 10 - designed to trip in 10 seconds at 600% of its normal current rating. Class 20 - designed to trip in 20 seconds at 600% of its normal current rating.

Time/Minutes

6.00 Trip/minutes Class 30 5.00 4.00 3.00 2.00 1.00 0.00 100% 200% 300% 400% 500% 600%

Class 30 - designed to trip in 30 seconds at 600% of its normal current rating.

Percent Load

85

Melting Alloy Type

10.00 9.00 8.00 7.00 Trip/minutes Class 20 Trip/minutes Class 10

Melting alloy type overload relays are normally identified by class designations Class 10 - designed to trip in 10 seconds at 600% of its normal current rating. Class 20 - designed to trip in 20 seconds at 600% of its normal current rating.

Time/Minutes

6.00 Trip/minutes Class 30 5.00 4.00 3.00 2.00 1.00 0.00 100% 200% 300% 400% 500% 600%

Class 30 - designed to trip in 30 seconds at 600% of its normal current rating.

Percent Load

Magnetic Type

A magnetic type overload has a current coil that functions as a solenoid and pulls in at a specific motor current. When the coil pulls in it opens the motor circuit and stops the motor. Normally, the trip time and trip current can be adjusted from potentiometers on the overload. Magnetic type overloads are typically found in high temperature environments or on motors with high inrush currents. There is no cool off time required for this type of overload.

L1

L2

L3
NO NO

Trip Time
Trip Current

NC NC

T1

T2

T3

86

Bi-Metallic Type

A bi-metallic type overload works on the same principle as an old fashioned home thermostat. Two dissimilar metals are bonded together. As the motor temperature increases the metals start to bend. At a specified temperature the bending metal trips a mechanism and opens the motor circuit. Bi-metallic type Spring overloads are normally found in critical applications that require the Bimotor to run very close to failure, metallic such as grocery store freezers, Strip unmanned pumping stations or chemical process pumps. Bi-metallic type overload normally reset automatically.

T1

L1
87

Bi-Metallic Type

A bi-metallic type overload works on the same principle as an old fashioned home thermostat. Two dissimilar metals are bonded together. As the motor temperature increases the metals start to bend. At a specified temperature the bending metal trips a mechanism and opens the motor circuit. Bi-metallic type Spring overloads are normally found in critical applications that require the Bimotor to run very close to failure, metallic such as grocery store freezers, Strip unmanned pumping stations or chemical process pumps. Bi-metallic type overload normally reset automatically.

T1

L1

Bi-metallic Thermo Disc

Bi-metallic thermo discs function the same as bi-metallic overloads. The major difference is that the thermo disc is actually inserted into the motor frame. When the motor temperature increases to an unacceptable level, the disc opens a normally closed contact that turns off the motor circuit.

88

Thermistor

Another form of motor overload protection is a thermistor. A thermistor is a small resistive device that is imbedded in the stator windings of the motor. The thermistor sends a signal to a controller that has been calibrated to protect the motor. At a specific temperature the controller activates a normally closed contact and opens the motor circuit.

Thermistor

NC NC

89

Electronic Thermal
80 70 60

Time/Minutes

50 40 30 20 10 0 50% 75%

Trip/minutes at 0Hz Trip/minutes at 6.7Hz Trip/minutes at 13.4Hz Trip/minutes at 20Hz Trip/minutes at 33.3Hz Trip/minutes at 46.6Hz Trip/minutes at 60Hz

Another form of motor overload protection is an inverse time electronic thermal overload.

Typically found in the software of variable frequency drives, this function derives a set of curves based on output frequency and load to determine a trip time.
A typical set of curves is shown here.
90

100% 125% 150%

Percent Load

Electronic Thermal
80 70 60

Time/Minutes

50 40 30 20 10 0 50% 75%

Trip/minutes at 0Hz Trip/minutes at 6.7Hz Trip/minutes at 13.4Hz Trip/minutes at 20Hz Trip/minutes at 33.3Hz Trip/minutes at 46.6Hz Trip/minutes at 60Hz

Another form of motor overload protection is an inverse time electronic thermal overload.

Typically found in the software of variable frequency drives, this function derives a set of curves based on output frequency and load to determine a trip time.
A typical set of curves is shown here.

100% 125% 150%

Percent Load

Information and enrollment for Yaskawa Training Classes can be accessed via:
1-800-Yaskawa (927-5292); press 6 for Training Coordinator

assistance with class enrollment. email to [email protected]. The Training Coordinator will respond with answers and class enrollment assistance.

Visit www.yaskawa.com - Choose Training on the navigation bar to access class descriptions and schedules.

6/6/2002

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