Energy Tips – Motor

Motor Tip Sheet #14 • June 2008 Industrial Technologies Program

Suggested Actions When Should Inverter-Duty Motors Be Specified?

• Obtain information from drive
and motor manufacturers about Electronic adjustable speed drives (ASDs) used to be marketed as “usable with any
inverter rise times and cable standard motor.” However, premature failures of motor insulation systems began
length effects, and use this to occur with the introduction of fast-switching pulse-width modulated (PWM)
information to evaluate the ability drives. The switching rates of modern power semiconductors can lead to voltage
of existing motors to withstand overshoots. These voltage spikes can rapidly damage a motor’s insulation system,
drive-induced voltage stresses. resulting in premature failure of the motor.
• Damaging reflected waves are
generally not a problem when the Effects of ASDs on Induction Motors
distance between the motor and
the drive is less than 15 feet. The non-sinusoidal variable frequency output of PWM drives results in increased
• Voltage overshoots are more likely motor losses, inadequate ventilation at lower speeds, increased dielectric stresses on
to occur with smaller motors and motor windings, magnetic noise, and the creation of shaft currents. These effects
drives with faster rise times. can combine to damage a motor’s insulation and severely shorten a motor’s useful
• The potential for damaging operating life.
reflected waves is especially high
when multiple motors are run High switching rates of modern power semiconductors lead to rapid changes in
from a single ASD. voltage in relatively short periods of time (dv/dt, quantified in units of volts per
microsecond). Steep-fronted waves with large dv/dt or very fast rise times lead to
Resources voltage overshoots and other power supply problems.
U.S. Department of EnergyFor When the motor impedance is larger than the conductor cable impedance, the
additional information or resources voltage wave form will reflect at the
on motor and motor-driven system motor terminals, creating a standing
efficiency improvement measures, wave (see Figure 1). Longer motor
visit the BestPractices Web site cables favor the formation of higher
at www.eere.energy.gov/industry/ amplitude standing waves. Voltage
bestpractices, or contact the
spikes have been reported with peak
EERE Information Center at
(877) 337-3463.
values as high as 2150 volts in a 460
V system operating at 10% over­
National Electrical voltage. High voltage spikes can lead
Manufacturers Association to insulation breakdown, resulting in
(NEMA)Visit the NEMA Web phase-to-phase or turn-to-turn short
site at www.nema.org for informa­
circuits, with subsequent over-current
tion on motor standards, application
guides, and technical papers.
trips by the drive sensor. Figure 1. PWM pulse with reflected voltage
or ringing
Inverter-Duty Motor Designs
Solutions used to prevent motor failures due to voltage spikes include the use of
power conditioning equipment (filters, load reactors, and isolation transformers) and
placing restrictions on the distance or lead length between the drive and the motor.
Some drive installers also specify oversized motors or high-temperature-resistant
Class H insulation.
Inverter-duty motors are wound with voltage spike-resistant, inverter-grade magnet
wire to minimize adverse effects of ASD-produced waveforms. Improved insulation
systems do not degrade as readily when subjected to transient voltage spikes. A
greater thickness or build-up of premium varnish (through multiple dips and bakes)
minimizes the potential for internal voids, and a lower heat rise design results in
improved resistance to voltage stresses. Quality manufacturing also affects the
corona inception voltage (CIV) of a motor. The CIV is a measure of the ability of BestPractices is part of the Industrial
Technologies Program Industries of the
the motor’s windings to withstand voltage stresses and is the voltage at which Future strategy, which helps the country’s
partial discharges begin to occur. most energy-intensive industries improve
their competitiveness. BestPractices brings
Many manufacturers offer “inverter-friendly” insulation in their NEMA together emerging technologies and best
Premium® motors. These inverter-ready motors are suitable for variable torque energy-management practices to help
companies begin improving energy efficiency,
loads over a wide speed range. The National Electrical Manufacturers environmental performance, and productivity
Association (NEMA) specifies that insulation systems for low voltage (<= 600 V) right now.
inverter-duty motors be designed to withstand an upper limit of 3.1 times the
BestPractices emphasizes plant systems,
motor’s rated line-to-line voltage. This is equivalent to an upper limit of 1,426 where significant efficiency improvements
peak volts at the motor terminals for a 460 V rated motor. Rise times must equal and savings can be achieved. Industry gains
easy access to near-term and long-term
or exceed 0.1 microsecond. solutions for improving the performance of
motor, steam, compressed air, and process
The insulation system on a 208/230 volt motor is identical to that of a 460 V heating systems. In addition, the Industrial
motor. Thus, voltage spikes produced by inverters on 208 V or 230 V systems Assessment Centers provide comprehensive
are unlikely to cause insulation damage at any cable length or drive carrier industrial energy evaluations to small- and
medium-size manufacturers.
frequency.
Larger inverter-duty motors often have a constant speed auxiliary blower to
provide adequate cooling at low motor operating speeds. Above the 500 frame FOR ADDITIONAL INFORMATION,
size, inverter-duty motors should have both bearings insulated, and be PLEASE CONTACT:
equipped with a shaft grounding brush with a ground strap from the motor to
the drive case. EERE Information Center
1-877-EERE-INF
(1-877-337-3463)
Motor Selection Guidelines www.eere.energy.gov
• NEMA MG 1-2006 Part 30 provides performance standards for general-
purpose motors used with ASDs. When operated under usual service Industrial Technologies Program
conditions, no significant reduction in service life should occur if the peak Energy Efficiency
and Renewable Energy
voltage at the motor terminals is limited to 1000 V and rise times equal or U.S. Department of Energy
exceed 2 microseconds. Contact the motor manufacturer for guidance relating Washington, DC 20585-0121
to motor/drive compatibility when peak voltages or rise times are expected to www.eere.energy.gov/industry
exceed these limits. A definite-purpose inverter-duty motor and/or filters,
chokes, or other voltage conditioning equipment may be required.
• Specify inverter-duty motors when operating at extremely low speeds or when
operation over base speed is required.
• When an inverter-duty motor is required, ensure that it is designed and
manufactured to meet the most current specifications defined by NEMA MG 1
Section IV, “Performance Standards Applying to All Machines,” Part 31

“Definite-Purpose Inverter-Fed Polyphase Motors.”

A S TRONG E NERGY P ORTFOLIO

FOR A S TRONG A MERICA

Energy efficiency and clean, renewable

energy will mean a stronger economy, a
cleaner environment, and greater energy
independence for America. Working
with a wide array of state, community,
industry, and university partners, the U.S.
Department of Energy’s Office of Energy
Efficiency and Renewable Energy invests in
a diverse portfolio of energy technologies.

DOE/GO-102008-2620
June 2008