Table of Contents

Introduction ............................................................................. 2
Siemens AC Drives and Totally Integrated Automation ........... 4
Mechanical Basics .................................................................. 6
AC Motor Construction ......................................................... 15
Developing A Rotating Magnetic Field.................................. 19
Rotor Construction ................................................................ 22
NEMA Rotor Characteristics ................................................. 26
Electrical Components Of A Motor........................................ 29
Voltage And Frequency ......................................................... 31
Basic AC Drives .................................................................... 37
Siemens MICROMASTER and MIDIMASTER ...................... 46
MICROMASTER Junior ......................................................... 65
MICROMASTER 420............................................................. 69
Siemens MASTERDRIVE ...................................................... 74
Parameters and Function Blocks ........................................... 96
Applications ........................................................................ 102
Constant Torque Applications .............................................. 103
Variable Torque Applications ................................................ 107
Constant Horsepower Applications ...................................... 111
Multimotor Applications ....................................................... 113
Review Answers .................................................................. 115
Final Exam ............................................................................ 116

Introduction

Welcome to another course in the STEP 2000 series, Siemens

Technical Education Program, designed to prepare our
distributors to sell Siemens Energy & Automation products
more effectively. This course covers Basics of AC Drives and
related products.
Upon completion of Basics of AC Drives you should be able to:

Explain the concept of force, inertia, speed, and torque

Explain the difference between work and power

Describe the construction of a squirrel cage AC motor

Identify the nameplate information of an AC motor

necessary for application to an AC Drive

Describe the operation of a three-phase rotating magnetic

field

Calculate synchronous speed, slip, and rotor speed

Describe the relationship between V/Hz, torque, and

current

Describe the basic construction and operation of a PWM

type AC drive

Describe features and operation of the Siemens

MICROMASTER, MICROMASTER Junior,
MICROMASTER Vector, MIDIMASTER Vector,
MICROMASTER 420, and MASTERDRIVE VC

Describe the characteristics of constant torque, constant

horsepower, and variable torque applications

This knowledge will help you better understand customer

applications. In addition, you will be able to describe products to
customers and determine important differences between
products. You should complete Basics of Electricity before
attempting Basics of AC Drives. An understanding of many of
the concepts covered in Basics of Electricity is required for
Basics of AC Drives.
If you are an employee of a Siemens Energy & Automation
authorized distributor, fill out the final exam tear-out card and
mail in the card. We will mail you a certificate of completion if
you score a passing grade. Good luck with your efforts.
SIMOVERT is a registered trademark of Siemens AG.
National Electrical Manufacturers Association is located at 2101
L. Street, N.W., Washington, D.C. 20037. The abbreviation
NEMA is understood to mean National Electrical
Manufacturers Association.

Siemens AC Drives and

Totally Integrated Automation

This course focuses on several Siemens AC drives, which

include the MICROMASTER, MICROMASTER Vector,
MIDIMASTER Vector, MICROMASTER Junior, MICROMASTER
420, and MASTERDRIVE VC, which are important elements of
the TIA strategy.

Totally Integrated
Automation

Totally Integrated Automation (TIA) is more than a concept. TIA

is a strategy developed by Siemens that emphasizes the
seamless integration of automation products. The TIA strategy
incorporates a wide variety of automation products such as
programmable controllers, computer numerical controls, Human
Machine Interfaces (HMI), and drives which are easily
connected via open protocol networks.

PROFIBUS DP

An important aspect of TIA is the ability of devices to

communicate with each other over various network protocols,
such as Ethernet and PROFIBUS DP. PROFIBUS DP is an open
bus standard for a wide range of applications in various
manufacturing and automation applications. Siemens AC drives
can easily communicate with other control devices such as
programmable logic controllers (PLCs) and personal computers
(PCs) through the PROFIBUS-DP communication system and
other various protocols.

Mechanical Basics

In many commercial, industrial, and utility applications electric

motors are used to transform electrical energy into mechanical
energy. Those electric motors may be part of a pump or fan, or
they may be connected to some other form of mechanical
equipment such as a conveyor or mixer. In many of these
applications the speed of the system is determined primarily by
its mechanical design and loading. For an increasing number of
these applications, however, it is necessary to control the speed
of the system by controlling the speed of the motor.

Variable Speed Drives

The speed of a motor can be controlled by using some type of

electronic drive equipment, referred to as variable or adjustable
speed drives. Variable speed drives used to control DC motors
are called DC drives. Variable speed drives used to control AC
motors are called AC drives. The term inverter is also used to
describe an AC variable speed drive. The inverter is only one
part of an AC drive, however, it is common practice to refer to
an AC drive as an inverter.

Before discussing AC drives it is necessary to understand

some of the basic terminology associated with drive operation.
Many of these terms are familiar to us in some other context.
Later in the course we will see how these terms apply to AC
drives.

Force

In simple terms, a force is a push or a pull. Force may be caused

by electromagnetism, gravity, or a combination of physical
means.

Net Force

Net force is the vector sum of all forces that act on an object,
including friction and gravity. When forces are applied in the
same direction they are added. For example, if two 10 lb
forces were applied in the same direction the net force would
be 20 lb.

If 10 lb of force were applied in one direction and 5 lb of force

applied in the opposite direction, the net force would be 5 lb
and the object would move in the direction of the greater force.

If 10 lb of force were applied equally in both directions, the net

force would be zero and the object would not move.

Torque

Torque is a twisting or turning force that tends to cause an

object to rotate. A force applied to the end of a lever, for
example, causes a turning effect or torque at the pivot point.
Torque () is the product of force and radius (lever distance).
Torque () = Force x Radius
In the English system torque is measured in pound-feet (lb-ft) or
pound-inches (lb-in). If 10 lbs of force were applied to a lever 1
foot long, for example, there would be 10 lb-ft of torque.

An increase in force or radius would result in a corresponding

increase in torque. Increasing the radius to 2 feet, for example,
results in 20 lb-ft of torque.

Speed

An object in motion travels a given distance in a given time.

Speed is the ratio of the distance traveled to the time it takes to
travel the distance.

Linear Speed

The linear speed of an object is a measure of how long it takes

the object to get from point A to point B. Linear speed is usually
given in a form such as meters per second (m/s). For example,
if the distance between point A and point B were 10 meters,
and it took 2 seconds to travel the distance, the speed would be
5 m/s.

Angular (Rotational) Speed

The angular speed of a rotating object is a measurement of how

long it takes a given point on the object to make one complete
revolution from its starting point. Angular speed is generally
given in revolutions per minute (RPM). An object that makes ten
complete revolutions in one minute, for example, has a speed
of 10 RPM.

Acceleration

An object can change speed. An increase in speed is called

acceleration. Acceleration only occurs only when there is a
change in the force acting upon the object. An object can also
change from a higher to a lower speed. This is known as
deceleration (negative acceleration). A rotating object, for
example, can accelerate from 10 RPM to 20 RPM, or decelerate
from 20 RPM to 10 RPM.

10

Law of Inertia

Mechanical systems are subject to the law of inertia. The law of

inertia states that an object will tend to remain in its current
state of rest or motion unless acted upon by an external force.
This property of resistance to acceleration/deceleration is
referred to as the moment of inertia. The English system of
measurement is pound-feet squared (lb-ft2).
If we look at a continuous roll of paper, as it unwinds, we know
that when the roll is stopped, it would take a certain amount of
force to overcome the inertia of the roll to get it rolling. The force
required to overcome this inertia can come from a source of
energy such as a motor. Once rolling, the paper will continue
unwinding until another force acts on it to bring it to a stop.

Friction

A large amount of force is applied to overcome the inertia of the

system at rest to start it moving. Because friction removes
energy from a mechanical system, a continual force must be
applied to keep an object in motion. The law of inertia is still
valid, however, since the force applied is needed only to
compensate for the energy lost.
Once the system is in motion, only the energy required to
compensate for various losses need be applied to keep it in
motion. In the previous illustration, for example: these losses
include:

Friction within motor and driven equipment bearings

Windage losses in the motor and driven equipment
Friction between material on winder and rollers

11

Work

Whenever a force of any kind causes motion, work is

accomplished. For example, work is accomplished when an
object on a conveyor is moved from one point to another.

Work is defined by the product of the net force (F) applied and
the distance (d) moved. If twice the force is applied, twice the
work is done. If an object moves twice the distance, twice the
work is done.
W=Fxd
Power

Power is the rate of doing work, or work divided by time.

In other words, power is the amount of work it takes to move

the package from one point to another point, divided by the
time.

12

Horsepower

Power can be expressed in foot-pounds per second, but is often

expressed in horsepower (HP). This unit was defined in the 18th
century by James Watt. Watt sold steam engines and was asked
how many horses one steam engine would replace. He had
horses walk around a wheel that would lift a weight. He found
that each horse would average about 550 foot-pounds of work
per second. One horsepower is equivalent to 500 foot-pounds
per second or 33,000 foot-pounds per minute.

The following formula can be used to calculate horsepower

when torque (lb-ft) and speed (RPM) are known. It can be seen
from the formula that an increase of torque, speed, or both will
cause a corresponding increase in horsepower.

13

Review 1

14

1.

A ____________ is a push or a pull.

2.

An object has 20 pounds of force applied in one

direction and 5 pounds of force applied in the opposite
direction. The net force is ____________ pounds.

3.

A twisting or turning force that causes an object to

rotate is known as ____________ .

4.

If 40 pounds of force were applied to a lever 2 feet long,

the torque would be ____________ lb-ft.

5.

The law of ____________ states that an object will tend

to remain in its current state of rest or motion unless
acted upon by an external force.

6.

____________ is the ratio of distance traveled and time.

7.

The speed of a rotating object is generally given in

____________ per ____________ .

AC Motor Construction

AC induction motors are commonly used in industrial

applications. The following motor discussion will center around
three-phase, 460 VAC, asynchronous, induction motors. An
asynchronous motor is a type of motor where the speed of the
rotor is other than the speed of the rotating magnetic field. This
type of motor is illustrated. Electromagnetic stator windings are
mounted in a housing. Power connections, attached to the
stator windings, are brought out to be attached to a three-phase
power supply. On three-phase, dual-voltage motors nine leads
are supplied for power connections. Three power connection
leads are shown in the following illustration for simplicity. A
rotor is mounted on a shaft and supported by bearings. On selfcooled motors, like the one shown, a fan is mounted on the
shaft to force cooling air over the motor.

15

Nameplate

The nameplate of a motor provides important information

necessary when applying a motor to an AC drive. The following
drawing illustrates the nameplate of a sample 25 horsepower
AC motor.

PE

21 PLUSTM

PREMIUM EFFICIENCY
MILL AND CHEMICAL DUTY QUALITY INDUCTION MOTOR
DATE
4
017
ORD.NO. 51-502-033
CODE
TYPE
H.P.
AMPS.
R.P.M.
DUTY
CLASS
INSUL
SH. END
BRG.

FRAME

RG Z ESD
25
56.8/28.4
1750
CONT.
NEMA
F Design

SERVICE
FACTOR

VOLTS
HERTZ

40 C AMB.
K.V.A.
B
G
CODE
OPP. END
50BC03JPP3
BRG.

Siemens Energy & Automation, Inc.

284T
1.15
230/460
60
3 PH

NEMA
NOM.EFF.

93.0

LOW VOLT.
CONN.
5
6
4
7

458C02JPP3

Little Rock, AR

HIGH VOLT.
CONN.
MADE IN
USA

Connections

This motor can be used on either 230 VAC or 460 VAC systems.
A wiring diagram indicates the proper connection of the input
power leads for the desired voltage. The low voltage connection
is intended for use on 230 VAC with a maximum full load current
of 56.8 Amps. The high voltage connection is intended for use
on 460 VAC with a maximum full load current of 28.4 Amps.

Base Speed

Base speed is the nameplate speed, given in RPM, where the

motor develops rated horsepower at rated voltage and
frequency. It is an indication of how fast the output shaft will
turn the connected equipment when fully loaded and proper
voltage is applied at 60 hertz. The base speed of this motor is
1750 RPM at 60 Hz. If the connected equipment is operating at
less than full load, the output speed will be slightly greater than
base speed.
It should be noted that with European and Asian motors and
many special motors, such as those used in the textile industry,
base speed, frequency and voltage may be different than
standard American motors. This is not a problem, however,
because the voltage and frequency supplied to a variable speed
drive does not have to be the same as the motor. The supply
voltage to a variable speed drive has nothing to do with motor
voltage, speed or frequency. A variable speed drive can be set
up to work with any motor within a reasonable size range and
rating.

16

Service Factor

A motor designed to operate at its nameplate horsepower rating

has a service factor of 1.0. Some applications may require a
motor to exceed the rated horsepower. In these cases a motor
with a service factor of 1.15 can be specified. The service factor
is a multiplier that may be applied to the rated power. A 1.15
service factor motor can be operated 15% higher than the
motors nameplate horsepower. Motors with a service factor of
1.15 are recommended for use with AC drives. It is important to
note, however, that even though a motor has a service factor of
1.15 the values for current and horsepower at the 1.0 service
factor are used to program a variable speed drive.

Insulation Class

The National Electrical Manufacturers Association (NEMA) has

established insulation classes to meet motor temperature
requirements found in different operating environments. The
four insulation classes are A, B, F, and H. Class F is commonly
used. Class A is seldom used. Before a motor is started, its
windings are at the temperature of the surrounding air. This is
known as ambient temperature. NEMA has standardized on an
ambient temperature of 40 C, or 104 F for all motor classes.
Temperature will rise in the motor as soon as it is started. The
combination of ambient temperature and allowed temperature
rise equals the maximum winding temperature in a motor. A
motor with Class F insulation, for example, has a maximum
temperature rise of 105 C. The maximum winding temperature
is 145 C (40 ambient plus 105 rise). A margin is allowed to
provide for a point at the center of the motors windings where
the temperature is higher. This is referred to as the motors hot
spot.

The operating temperature of a motor is important to efficient

operation and long life. Operating a motor above the limits of
the insulation class reduces the motors life expectancy. A 10 C
increase in the operating temperature can decrease the life
expectancy of a motor as much as 50%.
17

NEMA Design

The National Electrical Manufacturers Association (NEMA) has

established standards for motor construction and performance.
The nameplate on page 20 is for a motor designed to NEMA B
specifications. NEMA B motors are commonly used with AC
drives. Any NEMA design (A, B, C, or D) AC motor will work
perfectly well with a properly sized variable speed drive.

Efficiency

AC motor efficiency is expressed as a percentage. It is an

indication of how much input electrical energy is converted to
output mechanical energy. The nominal efficiency of this motor
is 93.0%.

Converting KW to HP

Motor manufacturers may also use kilowatts (KW) instead of

horsepower.
To convert KW to HP use the following equation:
HP = 1.341 x KW
HP = 24

18

Developing A Rotating Magnetic Field

A rotating magnetic field must be developed in the stator of an

AC motor in order to produce mechanical rotation of the rotor.
Wire is coiled into loops and placed in slots in the motor
housing. These loops of wire are referred to as the stator
windings. The following drawing illustrates a three-phase stator.
Phase windings (A, B, and C) are placed 120 apart. In this
example, a second set of three-phase windings is installed. The
number of poles is determined by how many times a phase
winding appears. In this example, each phase winding appears
two times. This is a two-pole stator. If each phase winding
appeared four times it would be a four-pole stator.

Magnetic Field

When AC voltage is applied to the stator, current flows through

the windings. The magnetic field developed in a phase winding
depends on the direction of current flow through that winding.
The following chart is used here for explanation only. It
assumes that a positive current flow in the A1, B1 and C1
windings result in a north pole.

Winding
A1
A2
B1
B2
C1
C2

Current Flow Direction

Positive
Negative
North
South
South
North
North
South
South
North
North
South
South
North

19

It is easier to visualize a magnetic field if a time is picked when

no current is flowing through one phase. In the following
illustration, for example, a time has been selected during which
phase A has no current flow, phase B has current flow in a
negative direction and phase C has current flow in a positive
direction. Based on the above chart, B1 and C2 are south poles
and B2 and C1 are north poles. Magnetic lines of flux leave the
B2 north pole and enter the nearest south pole, C2. Magnetic
lines of flux also leave the C1 north pole and enter the nearest
south pole, B1. A magnetic field results indicated by the arrow.

The amount of flux lines () the magnetic field produces is

proportional to the voltage (E) divided by the frequency (F).
Increasing the supply voltage increases the flux of the
magnetic field. Decreasing the frequency increases the flux.

20

If the field is evaluated at 60 intervals from the starting point,

at point 1, it can be seen that the field will rotate 60. At point 1
phase C has no current flow, phase A has current flow in a
positive direction and phase B has current flow in a negative
direction. Following the same logic as used for the starting
point, windings A1 and B2 are north poles and windings A2
and B1 are south poles. At the end of six such intervals the
magnetic field will have rotated one full revolution or 360.

Synchronous Speed

The speed of the rotating magnetic field is referred to as

synchronous speed (NS). Synchronous speed is equal to 120
times the frequency (F), divided by the number of poles (P).

If the applied frequency of the two-pole stator used in the

previous example is 60 hertz, synchronous speed is 3600
RPM.

21

Rotor Construction

The most common type of rotor is the squirrel cage rotor. The
construction of the squirrel cage rotor is reminiscent of rotating
exercise wheels found in cages of pet rodents. The rotor
consists of a stack of steel laminations with evenly spaced
conductor bars around the circumference. The conductor bars
are mechanically and electrically connected with end rings. A
slight skewing of the bars helps to reduce audible hum. The
rotor and shaft are an integral part.

22

Rotating Magnet

There is no direct electrical connection between the stator and

the rotor or the power supply and the rotor of an induction
motor. To see how a rotor works, a magnet mounted on the shaft
can be substituted for the squirrel cage rotor. When the stator
windings are energized a rotating magnetic field is established.
The magnet has its own magnetic field that interacts with the
rotating magnetic field of the stator. The north pole of the
rotating magnetic field attracts the south pole of the magnet and
the south pole of the rotating magnetic field attracts the north
pole of the magnet. As the rotating magnetic field rotates, it
pulls the magnet along causing it to rotate. This type of design
is used on some motors and is referred to as a permanent
magnet synchronous motor.

Rotation of a
Squirrel Cage Rotor

The squirrel cage rotor of an AC motor acts essentially the

same as the magnet. When a conductor, such as the conductor
bars of the rotor, passes through a magnetic field a voltage (emf)
is induced in the conductor. The induced voltage causes current
flow in the conductor. The amount of induced voltage (E)
depends on the amount of flux () and the speed (N) at which
the conductor cuts through the lines of flux. The more lines of
flux, or the faster they are cut, the more voltage is induced.
Certain motor constants (k), determined by construction also
affect induced voltage. These constants, such as rotor bar shape
and construction, do not change with speed or load.

23

Current flows through the rotor bars and around the end ring.
The current flow in the conductor bars produces magnetic
fields around each rotor bar. The squirrel cage rotor becomes an
electromagnet with alternating north and south poles. The
magnetic fields of the rotor interact with the magnetic fields of
the stator. It must be remembered that the current and
magnetic fields of the stator and rotor are constantly changing.
As the stator magnetic field rotates, the rotor and shaft follow.

Slip

There must be a relative difference in speed between the rotor

and the rotating magnetic field. The difference in speed of the
rotating magnetic field, expressed in RPM, and the rotor,
expressed in RPM, is known as slip.
Slip is necessary to produce torque. If the rotor and the rotating
magnetic field were turning at the same speed no relative
motion would exist between the two, therefore no lines of flux
would be cut, and no voltage would be induced in the rotor.
Slip is dependent on load. An increase in load will cause the
rotor to slow down or increase slip. A decrease in load will
cause the rotor to speed up or decrease slip. Slip is expressed
as a percentage.

For example, a four-pole motor operated at 60 Hz has a

synchronous speed of 1800 RPM. If the rotor speed at full load
were 1750 RPM, the slip is 2.8%.

24

Review 2
1.

Given an AC motor with the following: a nameplate

amps of 10/5, and volts of 230/460, the full load amps at
460 volts is ____________ amps.

2.

A motor which is permitted to exceed the rated

horsepower by 15% has a service factor of
____________.

3.

A motor with a rating of 37 KW would have an

equivalent horsepower rating of ____________ HP.

4.

Stator windings in a three-phase, two-pole motor are

placed ____________ degrees apart.

5.

The synchronous speed of a four-pole stator with 60

Hertz applied is ____________ RPM.
The synchronous speed of a four-pole stator with 50
Hertz applied is ____________ RPM.

6.

An increase of stator voltage in a 3-phase AC motor will

cause the magnetic lines of flux to ____________ .

7.

An increase of stator frequency in a 3-phase AC motor

will cause the magnetic lines of flux to ____________ .

8.

____________ is the relative difference in speed

between the rotor and the rotating magnetic field.

25

NEMA Rotor Characteristics

The National Electrical Manufacturers Association (NEMA)

classifies motors according to locked rotor torque and current,
pull up torque, breakdown torque and percent slip. In addition,
full-load torque and current must be considered when
evaluating an application.
Most NEMA terms and concepts apply to motors operated from
60 Hz power lines, not variable speed drive operation. In
following sections we will see how an AC variable speed drive
can improve the starting and operation of an AC motor.
Locked Rotor Torque

Locked rotor torque, also referred to as starting torque, is

developed when the rotor is held at rest with rated voltage and
frequency applied. This condition occurs each time a motor is
started. When rated voltage and frequency are applied to the
stator there is a brief amount of time before the rotor turns.

Locked Rotor Current

Locked rotor current is also referred to as starting current. This is

the current taken from the supply line at rated voltage and
frequency with the rotor at rest.

Pull Up Torque

Pull up torque is the torque developed during acceleration from

start to the point breakdown torque occurs.

Breakdown Torque

Breakdown torque is the maximum torque a motor develops at

rated voltage and speed without an abrupt loss of speed.

Full-Load Torque

Full-load torque is the torque developed when the motor is

operating with rated voltage, frequency and load.

Full-Load Current

Full-load current is the current taken from the supply line at

rated voltage, frequency and load.

NEMA Classifications

Three-phase AC motors are classified by NEMA as NEMA A, B,

C and D. NEMA specifies certain operating characteristics for
motors when started by applying rated voltage and frequency
(across the line starting). A NEMA B motor, for example,
typically requires 600% starting current and 150% starting
torque. These considerations do not apply to motors started
with an AC drive. NEMA B design motors are the most
common and most suitable for use on AC drives.

26

NEMA B Speed and Torque

A graph similar to the one illustrated below is used to show the

relationship between motor speed and torque of a NEMA B
motor. When rated voltage and frequency are applied to the
motor, synchronous speed goes to 100% immediately. The rotor
must perform a certain amount of work to overcome the
mechanical inertia of itself and the connected load.
Typically a NEMA B motor will develop 150% torque to start the
rotor and load. As the rotor accelerates the relative difference in
speed between synchronous speed and rotor speed decreases
until the rotor reaches its operating speed. The operating speed
of a NEMA B motor with rated voltage, frequency and load is
approximately 97% (3% slip) of synchronous speed. The
amount of slip and torque is a function of load. With an increase
in load there is a corresponding increase in slip and torque. With
a decrease in load there is a corresponding decrease in slip and
torque.

27

Starting Current

28

When a motor is started, it must perform work to overcome the

inertia of the rotor and attached load. The starting current
measured on the incoming line (IS) is typically 600% of full-load
current when rated voltage and frequency is first applied to a
NEMA B motor. Stator current decreases to its rated value as
the rotor comes up to speed. The following graph applies to
across the line operation, not variable speed drive operation.

Electrical Components Of A Motor

Up to this point we have examined the operation of an AC

motor with rated voltage and frequency applied. Many
applications require the speed of an AC motor to vary, which is
easily accomplished with an AC drive. However, operating a
motor at other than rated voltage and frequency has an effect on
motor current and torque. In order to understand how a motors
characteristics can change we need a better understanding of
both AC motors and AC drives.
The following diagram represents a simplified equivalent circuit
of an AC motor. An understanding of this diagram is important
in the understanding of how an AC motor is applied to an AC
drive.
VS
RS
LS
IS
E
LM
IM
RR
LR
IW

Line voltage applied to stator power leads

Stator resistance
Stator leakage inductance
Stator current
Air gap or magnetizing voltage
Magnetizing inductance
Magnetizing current
Rotor resistance (varies with temperature)
Rotor leakage inductance
Working or torque producing current

29

Line Voltage

Voltage (VS) is applied to the stator power leads from the AC

power supply. Voltage drops occur due to stator resistance (RS).
The resultant voltage (E) represents force (cemf) available to
produce magnetizing flux and torque.

Magnetizing Current

Magnetizing current (IM) is responsible for producing

magnetic lines of flux which magnetically link with the rotor
circuit. Magnetizing current is typically about 30% of rated
current. Magnetizing current, like flux (), is proportional to
voltage (E) and frequency (F).

Working Current

The current that flows in the rotor circuit and produces torque is
referred to as working current (IW). Working current is a function
of the load. An increase in load causes the rotor circuit to work
harder increasing working current (IW). A decrease in load
decreases the work the rotor circuit does decreasing working
current (IW).

Stator Current

Stator current (IS) is the current that flows in the stator circuit.
Stator current can be measured on the supply line and is also
referred to as line current. A clamp-on ammeter, for example, is
frequently used to measure stator current. The full-load ampere
rating on the nameplate of a motor refers to stator current at
rated voltage, frequency and load. It is the maximum current the
motor can carry without damage. Stator current is the vector
sum of working current (IW) and magnetizing current (IM).
Typically magnetizing current (IM) remains constant. Working
current (IW) will vary with the applied load which causes a
corresponding change in stator current (IS).

30

Voltage And Frequency

Volts per Hertz

A ratio exists between voltage and frequency. This ratio is

referred to as volts per hertz (V/Hz). A typical AC motor
manufactured for use in the United States is rated for 460 VAC
and 60 Hz. The ratio is 7.67 volts per hertz. Not every motor has
a 7.67 V/Hz ratio. A 230 Volt, 60 Hz motor, for example, has a 3.8
V/Hz ratio.

Flux (), magnetizing current (IM), and torque are all dependent
on this ratio. Increasing frequency (F) without increasing
voltage (E), for example, will cause a corresponding increase in
speed. Flux, however, will decrease causing motor torque to
decrease. Magnetizing current (IM) will also decrease. A
decrease in magnetizing current will cause a corresponding
decrease in stator or line (IS) current. These decreases are all
related and greatly affect the motors ability to handle a given
load.

31

Constant Torque

AC motors running on an AC line operate with a constant flux

() because voltage and frequency are constant. Motors
operated with constant flux are said to have constant torque.
Actual torque produced, however, is determined by the demand
of the load.

An AC drive is capable of operating a motor with constant flux

() from approximately zero (0) to the motors rated nameplate
frequency (typically 60 Hz). This is the constant torque range. As
long as a constant volts per hertz ratio is maintained the motor
will have constant torque characteristics. AC drives change
frequency to vary the speed of a motor and voltage
proportionately to maintain constant flux. The following graphs
illustrate the volts per hertz ratio of a 460 volt, 60 hertz motor
and a 230 volt, 60 Hz motor. To operate the 460 volt motor at
50% speed with the correct ratio, the applied voltage and
frequency would be 230 volts, 30 Hz. To operate the 230 volt
motor at 50% speed with the correct ratio, the applied voltage
and frequency would be 115 volts, 30 Hz. The voltage and
frequency ratio can be maintained for any speed up to 60 Hz.
This usually defines the upper limits of the constant torque
range.

32

Reduced Voltage and

Frequency Starting

You will recall that a NEMA B motor started by connecting it to

the power supply at full voltage and frequency will develop
approximately 150% starting torque and 600% starting current.
An advantage of using AC drives to start a motor is the ability to
develop 150% torque with a starting current of 150% or less.
This is possible because an AC drive is capable of maintaining
a constant volts per hertz ratio from approximately zero speed
to base speed, thereby keeping flux () constant. Torque is
proportional to the square of flux developed in the motor.
T 2
The torque/speed curve shifts to the right as frequency and
voltage are increased. The dotted lines on the torque/speed
curve illustrated below represent the portion of the curve not
used by the drive. The drive starts and accelerates the motor
smoothly as frequency and voltage are gradually increased to
the desired speed. Slip, in RPM, remains constant throughout
the speed range. An AC drive, properly sized to a motor, is
capable of delivering 150% torque at any speed up to the
speed corresponding to the incoming line voltage. The only
limitations on starting torque are peak drive current and peak
motor torque, whichever is less.

Some applications require higher than 150% starting torque. A

conveyor, for example, may require 200% starting torque. If a
motor is capable of 200% torque at 200% current, and the
drive is capable of 200% current, then 200% motor torque is
possible. Typically drives are capable of producing 150% of
drive nameplate rated current for one (1) minute. A drive with a
larger current rating would be required. It is appropriate to
supply a drive with a higher continuous horsepower rating than
the motor when high peak torque is required.
33

Constant Horsepower

Some applications require the motor to be operated above base

speed. The nature of these applications requires less torque at
higher speeds. Voltage, however, cannot be higher than the
available supply voltage. This can be illustrated using a 460 volt,
60 Hz motor. Voltage will remain at 460 volts for any speed
above 60 Hz. A motor operated above its rated frequency is
operating in a region known as a constant horsepower.
Constant volts per hertz and torque is maintained to 60 Hz.
Above 60 Hz the volts per hertz ratio decreases.
Frequency

V/Hz

30 Hz
60 Hz
70 Hz
90 Hz

7.67
7.67
6.6
5.1

Flux () and torque (T) decrease:

Horsepower remains constant as speed (N) increase and torque

decreases in proportion. The following formula applies to speed
in revolutions per minute (RPM).

34

Field Weakening

Motors operated above base frequency can also be said to be in

field weakening. Field weakening occurs whenever there is an
increase in frequency without a corresponding increase in
voltage. Although an AC drive could be setup for field
weakening at any speed, it typically only occurs beyond base
frequency.
We have seen that below base speed, in the constant torque
region, a motor can develop rated torque at any speed.
However, above base speed, in the constant horsepower
region, the maximum permissible torque is greatly reduced.

Field Weakening Factor

A field weakening factor (FFW) can be used to calculate the

amount of torque reduction necessary for a given extended
frequency.

For example, a 60 Hz motor can only develop 44% rated torque

at 90 Hz and 25% rated torque at 120 Hz.

35

Selecting a Motor

AC drives often have more capability than the motor. Drives can
run at higher frequencies than may be suitable for an
application. In addition, drives can run at low speeds. Selfcooled motors may not develop enough air flow for cooling at
reduced speeds and full load. Consideration must be given to
the motor.
The following graph indicates the speed and torque range of a
sample motor. Each motor must be evaluated according to its
own capability. The sample motor can be operated continuously
at 100% torque up to 60 Hz. Above 60 Hz the V/Hz ratio
decreases and the motor cannot develop 100% torque. This
motor can be operated continuously at 25% torque at 120 Hz.
The motor is also capable of operating above rated torque
intermittently. The motor can develop as much as 150%* torque
for starting, accelerating or load transients, if the drive can
supply the current. At 120 Hz the motor can develop 37.5%
torque intermittently.

The sample motor described above is capable of operating at

100% rated torque continuously at low frequencies. Many
motors are not capable of operating continuously at 100%
continuous torque at low frequencies. Each motor must be
evaluated before selecting it for use on an AC drive.

*
36

Torque may be higher than 150% if the drive is capable of

higher current.

Basic AC Drives

AC drives, inverters, and adjustable frequency drives are all

terms that are used to refer to equipment designed to control
the speed of an AC motor. The term SIMOVERT is used by
Siemens to identify a SIemens MOtor inVERTer (AC drive). AC
drives receive AC power and convert it to an adjustable
frequency, adjustable voltage output for controlling motor
operation. A typical inverter receives 480 VAC, three-phase, 60
Hz input power and provides power to the motor which can be
steplessly adjusted through the speed range. The three
common inverter types are the variable voltage inverter (VVI),
current source inverter (CSI), and pulse width modulation
(PWM). Another type of AC drive is a cycloconverter. These are
commonly used for very large motors and will not be described
in this course. All AC drives convert AC to DC, and then through
various switching techniques invert the DC into a variable
voltage, variable frequency output.

37

Variable Voltage
Inverter (VVI)

The variable voltage inverter (VVI) uses an SCR converter

bridge to convert the incoming AC voltage into DC. The SCRs
provide a means of controlling the value of the rectified DC
voltage from 0 to approximately 600 VDC. The L1 choke and C1
capacitor(s) make up the DC link section and smooth the
converted DC voltage. The inverter section consists of six
switching devices. Various devices can be used such as
thyristors, bipolar transistors, MOSFETS, and IGBTs. The
following schematic shows an inverter that utilizes bipolar
transistors. Control logic (not shown) uses a microprocessor to
switch the transistors on and off providing a variable voltage and
frequency to the motor.

This type of switching is often referred to as six-step because it

takes six 60 steps to complete one 360 cycle. Although the
motor prefers a smooth sine wave, a six-step output can be
satisfactorily used. The main disadvantage is torque pulsation
which occurs each time a switching device, such as a bipolar
transistor, is switched. The pulsations can be noticeable at low
speeds as speed variations in the motor. These speed variations
are sometimes referred to as cogging. The non-sinusoidal
current waveform causes extra heating in the motor requiring a
motor derating.

38

Current Source Inverter

The current source inverter (CSI) uses an SCR input to produce

a variable voltage DC link. The inverter section also uses SCRs
for switching the output to the motor. The current source
inverter controls the current in the motor. The motor must be
carefully matched to the drive.

Current spikes, caused by switching, can be seen in the output.

At low speeds current pulses can causes the motor to cog.

39

Pulse Width Modulation

Pulse width modulation (PWM) drives, like the Siemens

MICROMASTER, MICROMASTER Vector, MIDIMASTER Vector,
MICROMASTER 420, and MASTERDRIVE VC, provide a more
sinusoidal current output to control frequency and voltage
supplied to an AC motor. PWM drives are more efficient and
typically provide higher levels of performance. A basic PWM
drive consists of a converter, DC link, control logic, and an
inverter.

Converter and DC Link

The converter section consists of a fixed diode bridge rectifier

which converts the three-phase power supply to a DC voltage.
The L1 choke and C1 capacitor(s) smooth the converted DC
voltage. The rectified DC value is approximately 1.35 times the
line-to-line value of the supply voltage. The rectified DC value is
approximately 650 VDC for a 480 VAC supply.

40

Control Logic and Inverter

Output voltage and frequency to the motor are controlled by the

control logic and inverter section. The inverter section consists
of six switching devices. Various devices can be used such as
thyristors, bipolar transistors, MOSFETS and IGBTs. The
following schematic shows an inverter that utilizes IGBTs. The
control logic uses a microprocessor to switch the IGBTs on and
off providing a variable voltage and frequency to the motor.

IGBTs

IGBTs (insulated gate bipolar transistor) provide a high

switching speed necessary for PWM inverter operation. IGBTs
are capable of switching on and off several thousand times a
second. An IGBT can turn on in less than 400 nanoseconds and
off in approximately 500 nanoseconds. An IGBT consists of a
gate, collector and an emitter. When a positive voltage (typically
+15 VDC) is applied to the gate the IGBT will turn on. This is
similar to closing a switch. Current will flow between the
collector and emitter. An IGBT is turned off by removing the
positive voltage from the gate. During the off state the IGBT
gate voltage is normally held at a small negative voltage (-15
VDC) to prevent the device from turning on.

41

Using Switching Devices to

Develop AC Output

42

In the following example, one phase of a three-phase output is

used to show how an AC voltage can be developed. Switches
replace the IGBTs. A voltage that alternates between positive
and negative is developed by opening and closing switches in a
specific sequence. For example, during steps one and two A+
and B- are closed. The output voltage between A and B is
positive. During step three A+ and B+ are closed. The
difference of potential from A to B is zero. The output voltage is
zero. During step four A- and B+ are closed. The output voltage
from A to B is negative. The voltage is dependent on the value
of the DC voltage and the frequency is dependent on the speed
of the switching. An AC sine wave has been added to the
output (A-B) to show how AC is simulated.

PWM Output

There are several PWM modulation techniques. It is beyond the

scope of this book to describe them all in detail. The following
text and illustrations describe a typical pulse width modulation
method. An IGBT (or other type switching device) can be
switched on connecting the motor to the positive value of DC
voltage (650 VDC from the converter). Current flows in the
motor. The IGBT is switched on for a short period of time,
allowing only a small amount of current to build up in the motor
and then switched off. The IGBT is switched on and left on for
progressively longer periods of time, allowing current to build
up to higher levels until current in the motor reaches a peak. The
IGBT is then switched on for progressively shorter periods of
time, decreasing current build up in the motor. The negative
half of the sine wave is generated by switching an IGBT
connected to the negative value of the converted DC voltage.

43

PWM Voltage and Current

The more sinusoidal current output produced by the PWM

reduces the torque pulsations, low speed motor cogging, and
motor losses noticeable when using a six-step output.

The voltage and frequency is controlled electronically by

circuitry within the AC drive. The fixed DC voltage (650 VDC) is
modulated or clipped with this method to provide a variable
voltage and frequency. At low output frequencies a low output
voltage is required. The switching devices are turned on for
shorter periods of time. Voltage and current build up in the
motor is low. At high output frequencies a high voltage is
required. The switching devices are turned on for longer periods
of time. Voltage and current build up in the motor increases.

44

Review 3
1.

The volts per hertz ratio of a 460 volt, 60 Hz motor is

____________ .

2.

An increase in voltage will cause flux () to

____________, and torque (T) capability to ____________
.

3.

A motor operated within a speed range that allows a

constant volts per hertz ratio is said to be constant
____________ .
a. horsepower

b.

torque

4.

If torque decreases proportional to speed (RPM)

increasing, then ____________ is constant.

5.

Siemens uses the term ____________ to identify a

Siemens inverter (AC drive).

6.

On a PWM drive with a 480 VAC supply, the

approximate voltage after being converted to DC is
___________ VDC.

7.

IGBTs are capable of being switched several

____________ a second.
a. times
c. thousand times

8.

b.
d.

hundred times
million times

A PWM output is preferred to a six-step output because

____________
a. PWM provides a more sinusoidal output
b. Cogging is more noticeable on a six-step
c. The non-sinusoidal waveform of a six-step
increases motor heat
d. a, b, and c

9.

To obtain a lower voltage and frequency output on a

PWM inverter, control circuitry will switch IGBTs on for
____________ periods of time.
a. shorter
b. longer

45

Siemens MICROMASTER and MIDIMASTER

Siemens offers a broad range of AC drives. The Siemens

MICROMASTER, MICROMASTER VECTOR and MIDIMASTER
Vector are adjustable frequency AC drives that use a built-in
microprocessor to control the operation of the drive. The
inverters are very compact and designed for operation
anywhere in the world.

46

Enclosures

The National Electrical Manufacturers Association (NEMA) has

specified standards for equipment enclosures. The
MICROMASTER and MICROMASTER Vector are supplied in a
protected chassis and a NEMA Type 1 enclosure. The
MIDIMASTER Vector is supplied in a NEMA Type 1 and NEMA
Type 12/4 enclosure.
NEMA Type

Definition

Indoor use primarily to provide a degree of

protection against limited amounts of falling dirt.

Indoor or outdoor use primarily to provide a degree

of protection against windblown dust and rain,
splashing water, hose-directed water, and damage
from external ice formation.

4X

12

Indoor or outdoor use primarily to provide a degree

of protection against corrosion, windblown dust
and rain, splashing water, hose-directed water, and
damage from external ice formation.
Indoor use primarily to provide a degree of
protection against circulating dust, falling dirt, and
dripping noncorrosive liquids.

Ambient Temperature

The MICROMASTER and MICROMASTER Vector are rated for

operation in an ambient temperature of 0 to 50 C. The
MIDIMASTER Vector is rated for operation in an ambient
temperature of 0 to 40 C.

Elevation

The MICROMASTER, MICROMASTER Vector, and

MIDIMASTER Vector are rated for operation below 3300 feet. At
higher elevations the air is thinner, consequently the drive cant
dissipate heat as effectively and the drive must be derated.

47

Distance to Motor

All motor cables have line-to-line and line-to-ground

capacitance. The longer the cable, the greater the capacitance.
Some types of cables, such as shielded cable or cables in metal
conduit, have greater capacitance. Spikes occur on the output of
all PWM drives because of the charging current of the cable
capacitance. Higher voltage (460 VAC) and higher capacitance
(long cables) result in higher current spikes. Voltage spikes
caused by long cable lengths can potentially shorten the life of
the inverter and the motor.
The maximum distance between a motor and the
MICROMASTER, MICROMASTER Vector, and the
MIDIMASTER Vector is 50 meters (164 feet). If shielded cable is
used, or if cable is run through a metal conduit, the maximum
distance is 25 meters (82 feet). When considering an application
where distance may be a problem, contact your local Siemens
representative.

48

Supply Voltage
and Frequency

The MICROMASTER, MICROMASTER Vector, and

MIDIMASTER Vector have an input voltage range that allows
them to be used worldwide. The acceptable input frequency
ranges from 47 Hz to 63 Hz. The following tables reflect ratings
available at the time this book was printed. A MICROMASTER
may also be referred to by a model series number, 6SE92. The
MICROMASTER Vector and the MIDIMASTER Vector may also
be referred to by a model series number, 6SE32.

Ratings

The following tables reflect ratings available for 6SE92s and

6SE32s.

MICROMASTER
Part Number

Model
Number

Motor
Power
HP

Rated
Current1
(NEC)

1 ph 230V +/-15% with built in filter (class A)

6SE92107BA40
MM12
1/6
.76
6SE92115BA40
MM25
1/3
1.18
6SE92121BA40
MM37
1/2
2
6SE92128BA40
MM55
3/4
2.8
6SE92136BA40
MM75
1
3.6
6SE92152BB40
MM110
1.5
5.2
6SE92168BB40
MM150
2
6.8
6SE92210BC40
MM220
3
9.6
6SE92213BC40
MM300
4
na
1 ph/3 ph 230V +/-15% (unfiltered)
6SE92107CA40
MM12/2
1/6
.76
6SE92115CA40
MM25/2
1/3
1.18
6SE92121CA40
MM37/2
1/2
2
6SE92128CA40
MM55/2
3/4
2.8
6SE92136CA40
MM75/2
1
3.6
6SE92152CB40 MM110/2
1.5
5.2
6SE92168CB40 MM150/2
2
6.8
6SE92210CC40 MM220/2
3
9.6
6SE92213CC40 MM300/2
4
na
6SE92218CC13 MM400/2 *
5
15.2
* 3 Phase Only

Part Number

Model
Number

Motor
Power
HP

230V
Nominal
60Hz
2
Current

230V
Maximum
Input
Continuous Current (Irms
Output
230V)
3
Current

0.76
1.18
2
2.8
3.6
5.2
6.8
9.6
11.8

0.9
1.7
2.3
2.9
3.9
5.3
7
10
13

0.76
1.18
2
2.8
3.6
5.2
6.8
9.6
11.8
15.2

0.9
1.7
2.3
2.9
3.9
5.3
7
10
13
17.5

1.8
3.2
4.6
6.2
8.2
11
14.4
20.2
28.3
1ph/3ph
1.8/1.1
3.2/1.9
4.6/2.7
6.2/3.6
8.2/4.7
11/6.4
14.4/8.3
20.2/11.7
28.3/16.3
21.1

460V
460V
Maximum
60Hz
Input Current
Continuous
Nominal
(Irms 400V)
Output
2
Current
3
Current

3 ph 400-500V +/-10% (unfiltered)

6SE92111DA40
MM37/3
1/2
1.1
1.2
6SE92114DA40
MM55/3
3/4
1.4
1.6
6SE92120DA40
MM75/3
1
1.9
2
6SE92127DA40 MM110/3
1.5
2.6
2.9
6SE92140DA40 MM150/3
2
3.4
3.8
6SE92158DB40 MM220/3
3
4.8
5.3
6SE92173DB40 MM300/3
4
6.3
7
6SE92210DC40 MM400/3
5
8.6
9.4
6SE92213DC40 MM550/3
7.5
11.0
12.1
6SE92215DC40 MM750/3
10
14.7
16.3
1
NEC currents based upon typical 4 pole motors.
2
Nominal current ratings with 150% overload for 60 seconds
3
Maximum continuous current without overload capability.

2.2
2.8
3.7
4.9
5.9
8.8
11.1
13.6
17.1
22.1

49

MICROMASTER Vector
Part Number

Model
Number

Motor
Power
HP

Rated
Current1
(NEC)

1 ph 230V +/-15% with built in filter (class A)

6SE32107BA40
MMV12
1/6
.76
6SE32115BA40
MMV25
1/3
1.18
6SE32121BA40
MMV37
1/2
2
6SE32128BA40
MMV55
3/4
2.8
6SE32136BA40
MMV75
1
3.6
6SE32152BB40
MMV110
1.5
5.2
6SE32168BB40
MMV150
2
6.8
6SE32210BC40
MMV220
3
9.6
6SE32213BC40
MMV300
4
na
1 ph / 3 ph 230V +/-15% (unfiltered)
6SE32107CA40 MMV12/2
1/6
.76
6SE32115CA40 MMV25/2
1/3
1.18
6SE32121CA40 MMV37/2
1/2
2
6SE32128CA40 MMV55/2
3/4
2.8
6SE32136CA40 MMV75/2
1
3.6
6SE32152CB40 MMV110/2
1.5
5.2
6SE32168CB40 MMV150/2
2
6.8
6SE32210CC40 MMV220/2
3
9.6
6SE32213CC40 MMV300/2
4
na
6SE32218CC40 MMV400/2 *
5
15.2
* 3 Phase Only

Part Number

Model
Number

Motor
Power
HP

3 ph 400-500V +/-10% (unfiltered)

6SE32111DA40 MMV37/3
1/2
6SE32114DA40 MMV55/3
3/4
6SE32120DA40 MMV75/3
1
6SE32127DA40 MMV110/3
1.5
6SE32140DA40 MMV150/3
2
6SE32158DB40 MMV220/3
3
6SE32173DB40 MMV300/3
4
6SE32210DC40 MMV400/3
5
6SE32213DC40 MMV550/3
7.5
6SE32215DC40 MMV750/3
10
1
2
3

50

230V
Nominal
60Hz
2
Current

230V
Maximum
Input
Continuous Current (Irms
Output
230V)
3
Current

0.76
1.18
2
2.8
3.6
5.2
6.8
9.6
11.8

0.9
1.7
2.3
2.9
3.9
5.3
7
10
13

0.76
1.18
2
2.8
3.6
5.2
6.8
9.6
11.8
15.2

0.9
1.7
2.3
2.9
3.9
5.3
7
10
13
17.5

Rated
Current1
(NEC)

460V
60Hz
Nominal
2
Current

460V
Maximum
Continuous
Output
Current3

Input
Current
(Irms)

1
1.4
1.8
2.6
3.4
4.8
na
7.6
11
14

1.1
1.4
1.9
2.6
3.4
4.8
6.3
8.6
11.0
14.7

1.2
1.6
2.0
2.9
3.8
5.3
7.0
9.4
12.1
16.3

2.2
2.8
3.7
4.9
5.9
8.8
11.1
13.6
17.1
22.1

1.8
3.2
4.6
6.2
8.2
11
14.4
20.2
28.3
1ph/3ph
1.8/1.1
3.2/1.9
4.6/2.7
6.2/3.6
8.2/4.7
11/6.4
14.4/8.3
20.2/11.7
28.3/16.3
21.1

NEC currents for typical 4 pole motors.

Nominal current ratings with 150% overload for 60 seconds and 200% overload for 3 seconds.
Maximum continuous current without overload capability.

MIDIMASTER Vector

Rated
Motor
Power
Current1
HP
(NEC)
3 ph 230V +/-15% NEMA 1 IP21 (unfiltere 230V
6SE32223CG40 MDV550/2
7.5
22
6SE32231CG40 MDV750/2
10
28
6SE32242CH40 MDV1100/2
15
42
6SE32254CH40 MDV1500/2
20
54
6SE32268CJ40 MDV1850/2
25
68
6SE32275CJ40 MDV2200/2
30
80
6SE32310CK40 MDV3000/2
40
104
6SE32313CK40 MDV3700/2
50
130
6SE32315CK40 MDV4500/2
60
154
3 ph 400V-500V +/-10% NEMA 1 IP21 (un 460V
6SE32224DG40 MDV1100/3
15
21
6SE32230DH40 MDV1500/3
20
27
6SE32235DH40 MDV1850/3
25
34
6SE32242DJ40 MDV2200/3
30
40
6SE32255DJ40 MDV3000/3
40
52
6SE32268DJ40 MDV3700/3
50
65
6SE32284DK40 MDV4500/3
60
77
6SE32310DK40 MDV5500/3
75
96
6SE32314DK40 MDV7500/3
100
124
3 ph 550-575V +/-10% NEMA 1 IP21(un 575V
6SE32139FG40 MDV220/4
3
3.9
6SE32161FG40 MDV400/4
5
6.1
6SE32190FG40 MDV550/4
7.5
9
6SE32211FG40 MDV750/4
10
11
6SE32217FG40 MDV1100/4
15
17
6SE32222FH40 MDV1500/4
20
22
6SE32227FH40 MDV1850/4
25
27
6SE32232FJ40 MDV2200/4
30
32
6SE32241FJ40 MDV3000/4
40
41
6SE32252FJ40 MDV3700/4
50
52
Part Number

Model
Number

Nominal Continuous
Output
60Hz
Current3
Current2
230V
230V
22
28
28
42
42
54
54
68
68
80
80
90
104
130
130
154
154
170
460V
460V
21
34
27
40
34
52
40
65
52
77
65
96
77
124
96
156
124
575V
575V
3.9
6.1
6.1
9
9
11
11
17
17
22
22
27
27
32
32
41
41
52
52
62

Input
Current
(Irms)
32
45
61
75
87
100
143
170
187
32
41
49
64
79
96
113
152
185
7
10
12
18
24
29
34
45
55
65

NEC currents based upon typical 4 pole motors

Nominal current ratings with 150% overload for 60 seconds and 200% for 3 seconds.

Maximum continuous current without overload capability. These current ratings are only
available when the inverter is programmed for variable torque mode.

Output Voltage
and Frequency

Output voltage is adjustable from 0 volts to approximately

input voltage. Depending on the drive, output frequency is
adjustable from 0 to a maximum of 650 Hz. Consideration must
be given to the motor and application, which may not be
capable of operating at 650 Hz. The MICROMASTER and
MIDIMASTER drives are capable of being set to a minimum and
maximum speed appropriate for the application. If the minimum
speed required is 10 Hz, and the maximum speed required is 60
Hz, then the drives can be programmed for a speed range of 10
to 60 Hz. Speed can be incremented in 0.01 Hz steps.
AC Drive

Output Frequency

MICROMASTER
MICROMASTER Vector

0 - 400 Hz
0 - 650 Hz
0 - 650 Hz (50 HP)
0 - 200 Hz (100 HP)

MIDIMASTER Vector

Frequency
Resolution
0.01 Hz
0.01 Hz
0.01 Hz

51

Internal Layout

52

The following illustration shows a typical internal layout of the

MICROMASTER and MIDIMASTER. Internal details vary from
unit to unit.

Parameter

A parameter is a variable that is given a constant value. For

example, ramp up time is parameter number P002. Ramp up
time can be set for any value from 0 to 650 seconds. When
setting up the drive a value of 10 seconds might be selected.
When given a start command it would take 10 seconds for the
drive to ramp up to full speed. Parameter adjustment on the
MICROMASTER and MIDIMASTER is simple. Standard
applications require no special settings, however, parameters
can be easily modified for special applications.
Programming is done on the MICROMASTER and
MIDIMASTER using an operator panel or an enhanced operator
panel (OPM2). Up to 31 standard inverters may be
simultaneously addressed through the OPM. Parameters, such
as ramp times, minimum and maximum frequencies, and
modes of operation are easily set. The P key toggles the
display between a parameter number and the value of the
parameter. The up and down pushbuttons scroll through
parameters and are used to set a parameter value. In the event
of a failure the inverter switches off and a fault code appears in
the display.

53

The MICROMASTER and MIDIMASTER have various

parameters for proper drive and motor operation. It is beyond
the scope of this book to describe in detail every parameter
available. Some of the key parameters are described in the
following text.

Ramp Function

54

A feature of AC drives is the ability to increase or decrease the

voltage and frequency to a motor gradually. This accelerates the
motor smoothly with less stress on the motor and connected
load. Parameters P002, P003 and P004 are used to set a ramp
function. Acceleration and deceleration are separately
programmable from 0 to 650 seconds. Acceleration, for
example, could be set for 10 seconds and deceleration could be
set for 60 seconds. Smoothing is a feature that can be added to
the acceleration/deceleration curve. This feature smooths the
transition between starting and finishing a ramp. Minimum and
maximum speed are set by parameters P012 and P013.

Analog Inputs (AIN)

Parameter P006 is used to select either an analog or digital

reference, or fixed frequency. Terminals one (1) through four (4)
are used to provide an analog reference that controls the speed
of the motor from 0 to 100%. Terminal one (1) is a +10 VDC
power supply that is internal to the drive. Terminal two (2) is the
return path, or ground, for the 10 Volt supply. An adjustable
resistor can be connected between terminals one and two.
Terminal three (3) is the positive (+) analog input to the drive.
The drive can also be programmed to accept 0 to 20 mA, or 4 to
20 mA speed reference signal. These signals are typically
supplied to the drive by other equipment such as a
programmable logic controller (PLC). Note that a jumper has
been connected between terminals two (2) and four (4). An
analog input cannot be left floating (open). If an analog input will
not be used it must be connected to terminal two (2).
The MICROMASTER Vector and the MIDIMASTER Vector have
two analog inputs, allowing for a PID control loop function. PID
control loops are used in process control to trim the speed.
Examples are temperature and pressure control.

55

Digital Inputs

The MICROMASTER has three digital inputs (DIN 1-3). The

MICROMASTER Vector and the MIDIMASTER Vector have six
digital inputs (DIN 1-6). A switch or contact is connected
between +15 VDC (P15V) and a digital input (DIN1 - DIN6). The
use of digital inputs is determined by parameters P051 through
P055 and P356. These can be programmed for various
functions. Digital input 1 (DIN1), for example, may be used to
start and stop the drive. When the switch between P15+ is
open the drive is stopped. When the switch between P15+ is
closed the drive supplies power to the motor. Other inputs can
be used for forward/reverse, preset speeds, jogging, or other
functions.

Thermistor

Some motors have a built in thermistor. If a motor becomes

overheated the thermistor acts to interrupt the power supply to
the motor. A thermistor can be connected to terminals 14 (PTC)
and 15 (0V). If the motor gets to a preset temperature as
measured by the thermistor, the driver will interrupt power to
the motor. The motor will coast to a stop. The display will
indicate a fault has occurred. Parameter P087 will enable the
thermistor. Virtually any standard thermistor as installed in
standard catalog motors will work. Snap-action thermostat
switches will also work.

56

Analog Outputs

Analog outputs can be used to monitor output frequency,

frequency setpoint, DC-link voltage, motor current, motor
torque, and motor RPM. The MICROMASTER and
MICROMASTER Vector have one analog output, connected to
+ve (terminal 12) and 0v (terminal 13). The MIDIMASTER Vector
has two analog outputs, connected to +ve (terminals 12 and 27)
and 0v (terminal 13). These are controlled by parameter P025
and P026 (MIDIMASTER Vector).

Relay Outputs

There are two programmable relay outputs (RL1 and RL2) for
indication of system status. These are controlled by parameters
P061 and P062. The RL1 output (terminals 18, 19, 20) can be
used for one normally closed (NC) or one normally open (NO)
output. The RL2 output (terminals 21, 22) can be used for a
normally open output. The relays can be programmed to
indicate various conditions such as the drive is running, a failure
has occurred, converter frequency is at 0 or converter frequency
is at minimum.

57

Serial Interface

The MICROMASTER and MIDIMASTER have an RS485 serial

interface that allows communication with computers (PCs) or
programmable logic controllers (PLCs). The standard RS485
protocol is called USS protocol and is programmable up to 19.2
K baud. Siemens PROFIBUS protocol is also available. It is
programmable up to 12 M baud. Contact your Siemens sales
representative for information on USS and PROFIBUS protocol.

Current Limit

The MICROMASTER, MICROMASTER Vector, and the

MIDIMASTER Vector are capable of delivering up to 150% of
drive rated current for one minute in constant torque mode. The
MICROMASTER Vector and the MIDIMASTER Vector are
capable of delivering 200% of drive rated current for three
seconds.
Sophisticated speed/time/current dependent overload functions
are used to protect the motor. The monitoring and protection
functions include a drive overcurrent fault, a motor overload
fault, a calculated motor over temperature warning, and a
measured motor over temperature fault (requires a device
inside the motor).

58

Low Speed Boost

Some applications, such as a conveyor, require more torque to

start and accelerate the load at low speed. Low speed boost is a
feature that allows the voltage to be adjusted at low speeds.
This will increase/decrease the torque. Low speed boost can be
adjusted high for applications requiring high torque at low
speeds. Some applications, such as a fan, dont require as much
starting torque. Low speed boost can be adjusted low for
smooth, cool, and quiet operation at low speed. An additional
starting boost is available for applications requiring high starting
torque.

Control Modes

The MICROMASTER has two modes of operation:

Linear voltage/frequency
Quadratic voltage/frequency
The MICROMASTER Vector and the MIDIMASTER Vector have
four modes of operation:
Linear voltage/frequency
Quadratic voltage/frequency
Flux Current Control (FCC)
Sensorless vector frequency control

Linear Voltage/Frequency

The MICROMASTER and MIDIMASTER can operate utilizing a

standard V/Hz curve. Using a 460 VAC, 60 Hz motor as an
example, constant volts per hertz is supplied to the motor at any
frequency between 0 and 60 Hz. This is the simplest type of
control and is suitable for general purpose applications.

59

Quadratic Operation

A second mode of operation is referred to as a quadratic

voltage/frequency curve. This mode provides a V/Hz curve that
matches the torque requirements of simple fan and pump
applications.

Flux Current Control

The third mode of operation, flux current control (FCC), is

available in the MICROMASTER Vector and the MIDIMASTER
Vector. Stator current (IS) is made up of active and reactive
current. The reactive current component of stator current
produces the rotating magnetic field. The active current
produces work. Motor nameplate data is entered into the drive.
The drive estimates motor magnetic flux based on the
measured reactive stator current and the entered nameplate
data. Proprietary internal computer algorithms attempt to keep
the estimated magnetic flux constant.
If the motor nameplate information has been correctly entered
and the drive properly set up, the flux current control mode will
usually provide better dynamic performance than simple V/Hz
control. Flux current control automatically adapts the drive
output to the load. The motor is always operated at optimum
efficiency. Speed remains reliably constant even under varying
load conditions.

60

Sensorless Vector Control

The fourth mode of operation is sensorless vector control (VC).

This mode of operation is available in the MICROMASTER
Vector and the MIDIMASTER Vector. In the past, the dynamic
response of a DC motor was generally considered significantly
better than an AC motor. An AC motor, however, is less
expensive and requires less maintenance than a DC motor.
Using a complex mathematical motor model and proprietary
internal computer algorithms vector control is able to exert the
necessary control over an AC motor so that its performance is
equal to that of a DC motor. Vector control, flux vector, and field
orientation are terms that describe this specialized control
technique of AC drives.
Vector control systems facilitate independent control of flux
producing and torque producing elements in an induction
motor. Sensorless vector control calculates rotor speed based
on the motor model, calculated CEMF, inverter output voltage,
and inverter output current. This results in improved dynamic
performance compared to other control methods.
When motor speed is calculated at very low speeds, based on a
small CEMF and known corrections for stator resistance, slight
variations in stator resistance and other parameters will have an
effect on speed calculation. This makes vector control without a
tachometer impractical below a few hertz.
Siemens sensorless vector control drives do operate smoothly
to low speed. Sensorless vector control drives will produce full
torque below a few hertz, and 150% or more torque at all
speeds.
There are some complicated techniques used to accomplish
this low speed torque with sensorless vector control. Expert
setup and commissioning may be required to achieve desired
operation at low speed.
Parameters for static torque, flux adaptation, slip compensation,
and other concepts are complex and beyond the scope of this
course.

61

Single-Quadrant Operation

In the speed-torque chart there are four quadrants according to

direction of rotation and direction of torque. A single-quadrant
drive operates only in quadrants I or III (shaded area). Quadrant I
is forward motoring or driving (CW). Quadrant III is reverse
motoring or driving (CCW). Reverse motoring is achieved by
reversing the direction of the rotating magnetic field. Motor
torque is developed in the positive direction to drive the
connected load at a desired speed (N). This is similar to driving a
car forward on a flat surface from standstill to a desired speed. It
takes more forward or motoring torque to accelerate the car
from zero to the desired speed. Once the car has reached the
desired speed your foot can be let off the accelerator a little.
When the car comes to an incline a little more gas, controlled by
the accelerator, maintains speed.

Coast-to-Stop

To stop an AC motor in single-quadrant operation voltage and

frequency can simply be removed and the motor allowed to
coast to a stop. This is similar to putting a car in neutral, turning
off the ignition and allowing the car to coast to a stop.

Controlled Deceleration

Another way is to use a controlled deceleration. Voltage and

frequency are reduced gradually until the motor is at stop. This
would be similar to slowly removing your foot from the
accelerator of a car. The amount of time required to stop a motor
depends on the inertia of the motor and connected load. The
more inertia the longer it will take to stop.

62

DC Injection Braking

The DC injection braking mode stops the rotating magnetic field

and applies a constant DC voltage to the motor windings,
helping stop the motor. Up to 250% of the motors rated current
can be applied. This is similar to removing your foot from the
accelerator and applying the brakes to bring the car to a stop
quickly.

Compound Braking

Compound braking uses a combination of the controlled

deceleration ramp and DC injection braking. The drive monitors
bus voltage during operation and triggers compound braking
when the bus exceeds a set threshold point. As the motor
decelerates to a stop a DC voltage is periodically applied to the
motor windings. The excess energy on the bus is dissipated in
the motor windings. This is similar to alternately applying the
brakes to slow a car, then allowing the mechanical inertia of the
engine to slow the vehicle until the car is brought to a stop.

Four-Quadrant Operation

The dynamics of certain loads may require four-quadrant

operation. When equipped with an optional braking resistor the
Siemens MICROMASTER and MIDIMASTER are capable of
four-quadrant operation. Torque will always act to cause the rotor
to run towards synchronous speed. If the synchronous speed is
suddenly reduced, negative torque is developed in the motor.
The motor acts like a generator by converting mechanical power
from the shaft into electrical power which is returned to the AC
drive. This is similar to driving a car downhill. The cars engine
will act as a brake. Braking occurs in quadrants II and IV.

63

Pulsed Resistor Braking

64

In order for an AC drive to operate in quadrant II or IV, a means

must exist to deal with the electrical energy returned to the
drive by the motor. Electrical energy returned by the motor can
cause voltage in the DC link to become excessively high when
added to existing supply voltage. Various drive components can
be damaged by this excessive voltage. An optional braking
resistor is available for the Siemens MICROMASTER and
MIDIMASTER. The braking resistor is connected to terminals
B+ and B-. The braking resistor is added and removed from the
circuit by an IGBT. Energy returned by the motor is seen on the
DC link. When the DC link reaches a predetermined limit the
IGBT is switched on by the control logic. The resistor is placed
across the DC link. Excess energy is dissipated by the resistor,
reducing bus voltage. When DC link voltage is reduced to a
safe level the IGBT is switched off, removing the resistor from
the DC link. This is referred to as pulsed resistor braking. This
process allows the motor to act as a brake, slowing the
connected load quickly.

MICROMASTER Junior

The MICROMASTER Junior is available in output power ranges

from 1/6 HP (120 W) to 2 HP (1500W). The MICROMASTER
Junior is integrated into the Siemens family of drives and the
parameter set is compatible with the MICROMASTER and
MIDIMASTER.

Wiring

Control wiring, such as speed reference and start/stop control is

connected to the control terminals. Power wiring, such as the
AC supply and the motor, is connected to the power terminals.

65

Control Wiring

The MICROMASTER Junior has provision for an analog input,

three digital inputs, RS485 serial interface, and an output relay.

Power Wiring

Output voltage is adjustable from 0 volts to approximately input

voltage. Output frequency is adjustable from 0.05 Hz to 200 Hz.

66

Operator Panel

The operator panel on the MICROMASTER Junior is identical to

the operator panel on the MICROMASTER and MIDIMASTER.
Parameters, such as ramp times, minimum and maximum
frequencies, and modes of operation are easily set. The P key
toggles the display between a parameter number and the value
of the parameter. The up and down pushbuttons scroll through
parameters and are used to set a parameter value. In the event
of a failure the inverter switches off and a fault code appears in
the display.

67

Features and Options

The MICROMASTER Junior has an input voltage range that

allows worldwide usage. The acceptable input frequency ranges
from 47 to 63 Hz. Acceptable input voltages are 1 or 3 230
VAC, or 3 400 to 460 VAC. The following table reflects ratings
available at the time this book was printed. A MICROMASTER
Junior may also be referred to by a model series number,
6SE91.

Model
Number

230 VAC 1
Class A Filter

Part Number
230 VAC 1,
3 w/o Class A
Filter

400-460 VAC
1, 3 w/o
Class A Filter

MMJ12 6SE9110-7BA53 6SE9110-7BA53

MMJ25 6SE9111-5BA53 6SE9111-5CA13
MMJ37 6SE9112-0BA53 6SE9112-0CA13 6SE9111-1JA13
MMJ55 6SE9112-6BA53 6SE9112-6CA13 6SE9111-4JA13
MMJ75 6SE9113-4BA53 6SE9113-4CA13 6SE9113-4JA13
MMJ110

6SE9112-7JA13

MMJ150

6SE9113-7JA13

Output
1/6 HP
120 W
1/3 HP
250 W
1/2 HP
370 W
3/4 HP
550 W
1 HP
750 W
1.5 HP
1.1 KW
2 HP
1.5 KW

Features

High Starting Torque

Programmable Acceleration/Deceleration with Smoothing
V/F Ratio, Linear or Fan Curve with Boost
Silent Motor Operation Using Special Pulse Techniques
Four Skip Frequencies
Automatic Restart on the Fly Option
Three Fixed Frequencies
Hoist Brake Interface
Most Recent Fault and Warning Memory
Overload Rating of 150% for One Minute

Options

68

Clear Text Operator Panel (OPM)

PROFIBUS
DIN Rail Mounting Bracket

MICROMASTER 420

The MICROMASTER 420 is another member of the Siemens

AC drive family. Like other members of the MICROMASTER
family, its range of supply voltages enable the MICROMASTER
420 to be used all over the world.
The MICROMASTER 420 is suitable for a variety of variablespeed applications, such as pumps, fans, and conveyor
systems. The MICROMASTER 420 is controlled by a
programmable digital microprocessor and is characterized by
ease of setup and use.

69

Design

70

The MICROMASTER 420 has a modular design that allows the

user configuration flexibility. The optional operator panels and
PROFIBUS module can be user installed. There are three
programmable digital inputs, one scalable analog input that can
also be used as a fourth digital input, one programmable analog
output, and one programmable relay output.

Operator Panels

There are two operator panels, the Basic Operator Panel (BOP)
and Advanced Operator Panel (AOP). Operator panels are used
for programming and drive operation (start, stop, jog, and
reverse).

BOP

Individual parameter settings can be made with the Basic

Operator Panel. Parameter values and units are shown on a
5-digit display. One BOP can be used for several units.

AOP

The Advanced Operator Panel enables parameter sets to be

read out or written (upload/download) to the MICROMASTER
420. Up to ten different parameter sets can be stored in the
AOP. The AOP features a multi-line, plain text display. Several
language sets are available. One AOP can control up to 31
drives.

Performance Features

The MICROMASTER 420 has the following features:

Flux Current Control (FCC)

Linear V/Hz Control
Quadratic V/Hz Control
Flying Restart
Slip Compensation
Automatic Restart
PI Feedback for Process Control
Programmable Acceleration/Deceleration
Ramp Smoothing
Fast Current Limit (FCL)
Compound Braking
71

Frame Sizes

72

The MICROMASTER 420 is available in three frame sizes with

power ratings from 1/6 HP to 15 HP.

Review 4
1.

The ____________ key on the Siemens MICROMASTER

and MIDIMASTER is used to toggle between a
parameter number and value.

2.

The maximum acceleration/deceleration ramp time on

the MICROMASTER, MICROMASTER Vector, and
MIDIMASTER Vector is ____________ seconds.

3.

A mode of operation available on MICROMASTER and

MIDIMASTER drives, which provides a V/Hz curve that
matches the torque requirements of simple fan and
pump applications is ____________ .
a. Linear voltage/frequency
b. Quadratic voltage/frequency
c. FCC
d. Sensorless vector frequency

4.

The ____________ mode of operation on the Siemens

MICROMASTER Vector and MIDIMASTER Vector use
internal computer algorithms to control an AC motor so
that its performance is equal to that of DC motor.
a. Linear voltage/frequency
b. Quadratic voltage/frequency
c. FCC
d. Sensorless vector frequency

5.

Forward regeneration occurs in quadrant ______ .

6.

The correct model number for a 2 HP MICROMASTER

Junior, operated on a 460 VAC lines is ____________ .

7.

380 VAC to 480 VAC, Frame size B of the

MICROMASTER 420 is available in power ratings from
____________ to ____________ HP.

73

Siemens MASTERDRIVE

Siemens MASTERDRIVEs provide an excellent solution for

industrial applications worldwide. Water-cooled versions can be
used in areas with high ambient temperature or where external
air cooling is unavailable. MASTERDRIVEs can be used for
variable-speed control on motors rated from 1 to 10,000 HP.
MASTERDRIVEs are available for all major worldwide 3-phase
supply voltages: 208-230, 380-460, 500-575, 660-690 volts. The
Siemens MASTERDRIVEs can also be referred to by a model
series number, 6SE70.

74

IEC and NEMA Protection

Depending on the size of the unit, Siemens MASTERDRIVEs

are available in a variety of enclosures. In addition to the basic
MASTERDRIVE 6SE70, drives designated 6SE71 are built to
International Electrotechnical Commission (IEC) standards.
Drives designated 6SE72 are built to National Electrical
Manufacturers Association (NEMA) standards. IEC and NEMA
enclosure standards provide various degrees of protection to
personnel and equipment.

IEC Standards

The IEC system of classification consists of the letters IP

followed by two numbers. The first number indicates the degree
of protection provided by the enclosure with respect to persons
and solid objects entering the enclosure. The second number
indicates the degree of protection against the ingress of water.
1st Number
0
1
2
3
4
5
6
2nd Number

Description
Not Protected
Protected Against Objects
Protected Against Objects
Protected Against Objects
Protected Against Objects
Protected Against Dust
Dust Tight

Greater than
Greater than
Greater than
Greater than

50 mm
12 mm
2.5 mm
1.0 mm

0
1
2
3
4
5
6

Not Protected
Protected Against Dripping Water
Protected Against Dripping Water when Tilted up to 15
Protected Against Spraying Water
Protected Against Splashing Water
Protected Against Water Jets
Protected Against Heavy Seas

Protected Against the Effects of Immersion for Specific

Time and Pressure

Protected Against Continuous Submersion Under

Conditions Specified by the Manufacturer

75

IP Enclosures Available

NEMA Standards

MASTERDRIVE

IP Ratings Available

Compact

IP20

Chassis

IP00, IP20

Cabinet

IP20, IP21, IP23, IP24, IP43,

Prepared for IP54

The National Electrical Manufacturers Association (NEMA) also

designates, by means of a type number, environmental
conditions an enclosure is suited for. MASTERDRIVEs are
available in NEMA 1, 4, and 12 enclosures.

NEMA Type
1

4X

12

76

Definition
Indoor use primarily to provide a degree of
protection against limited amounts of falling dirt.
Indoor or outdoor use primarily to provide a degree
of protection against windblown dust and rain,
splashing water, hose-directed water, and damage
from external ice formation.
Indoor or outdoor use primarily to provide a degree
of protection against corrosion, windblown dust
and rain, splashing water, hose-directed water, and
damage from external ice formation.
Indoor use primarily to provide a degree of
protection against circulating dust, falling dirt, and
dripping noncorrosive liquids.

Versions

There are two versions of the MASTERDRIVEs product: vector

control (VC) and motion control (MC).

Vector Control (VC)

One mode of operation in the MASTERDRIVEs is vector control

(VC), which is the focus of this part of the course. In the past, the
dynamic response of a DC motor was generally considered
significantly better than an AC motor. An AC motor, however, is
less expensive and requires less maintenance than a DC motor.
Using a complex mathematical motor model and proprietary
internal computer algorithms vector control is able to exert the
necessary control over an AC motor so that its performance is
equal to that of a DC motor. Vector control, flux vector, and field
orientation are terms that describe this specialized control
technique of AC drives.
Vector control drives have 4-quadrant operation and control
torque and speed continuously through zero speed, and can
hold a motor stationary against an applied torque. Speed control
is exact, even with varying loads. Speed control reaction time is
45 ms without tach feedback, and 20 ms with tach feedback.
Maximum torque is available up to base speed. Torque control
reaction time is 10 ms in torque control with feedback.

Motion Control (MC)

A second mode of operation available on the MASTERDRIVEs

is motion control (MC). Servo drives are designed to operate
with a specific motor and are designed to achieve speed
precision and fast response to a speed change. Servo
applications typically have rapid start-stop cycles, require zero
speed holding torque and high accelerating torque from zero
speed, and are used positioning applications. In a packaging
machine, for example, material may have to start and stop at
various positions along a conveyor system.
The STEP 2000 course, Basics of General Motion Control,
provides more information on the Siemens motion control
(MC) drive.

77

Ratings

The following graph shows horsepower ratings available for

VC MASTERDRIVEs.
HP

30

5000

10,000

660V - 15% up to
690V + 15%
50/60Hz 6%
500V - 15% up to
575V + 15%
50/60Hz 6%
380V - 15% up to
460V + 15%
50/60Hz 6%
208V - 15% up to
230V + 15%
50/60Hz 6%

AC - AC (AC to AC)

78

The terms AC - AC and DC - AC refers to methods of

configuring MASTERDRIVEs. AC - AC in the MASTERDRIVE VC
family refers to a single drive, connected to an AC source,
controlling an AC motor, an AC motor with a tach, or multimotor
applications. Various options allow for analog and encoder
tachometer types.

DC - AC (DC to AC)

The Siemens MASTERDRIVEs can also be configured so that a

common DC bus supplies power to several AC inverters.
Common DC bus systems also allow single and multimotor
combinations. This is referred to as the DC-AC version. An
advantage to this system is that energy regenerated by one
inverter can be consumed by another inverter on the same bus.

Braking Choices

The dynamics of certain loads require four-quadrant operation.

Torque will always act to cause the rotor to run towards
synchronous speed. If the synchronous speed is suddenly
reduced, negative torque is developed in the motor. This could
occur, for example when a stop command is initiated and the
drive tries to slow down to bring the motor to a stop. The motor
acts like a generator by converting mechanical power from the
shaft into electrical power which is returned to the AC Drive.
This is known as regeneration, and helps slow the motor.
Braking occurs in quadrants II and IV. When equipped with an
optional braking unit, Siemens MASTERDRIVEs are capable of
four-quadrant operation.

79

One method of dealing with negative torque and the current it

produces is controlled deceleration. Voltage and frequency is
reduced gradually until the motor is at stop. This would be
similar to slowly removing your foot from the accelerator of a
car. Many applications, however, require the motor to stop
quicker, and the drive must be capable of handling the excess
energy produced by motor when this is done.
Rectifier Regenerative
Front End

80

Another method of dealing with excessive regeneration is with

a rectifier regenerative front end. Diodes in the converter
section are replaced with SCRs and a second regen bridge is
added. An SCR functions similarly to a diode rectifier, except
that it has a gate lead, which is used to turn the SCR on. This
allows the control logic to control when the converter bridge
and regen bridge are turned on.

A simplified block diagram provides a clearer view of the regen

process. When the motor needs motoring energy to accelerate
or maintain speed against the inertia of a load, the converter
bridge is turned on. When the motor is in the regenerative
mode, it acts like a generator, supplying electrical energy back
to the DC link. When the DC link voltage reaches a
predetermined level the motoring SCRs are switched off and
the regen (generating) SCRs are switched on.

This allows the excess energy to be returned to the AC line in

the form of AC current.

81

ACTIVE FRONT END

An ACTIVE FRONT END (AFE) is another option available to

control regenerative voltage. With this option the diodes in the
converter bridge are replaced with IGBT modules and a Clean
Power Filter. The IGBT, controlled by control logic, operates in
both motoring and regenerating modes.

Harmonics are created by electronic circuits, such as the nonlinear loads of adjustable speed drives. Harmonics can cause
problems to connected loads. The base frequency is said to be
the fundamental frequency or first harmonic. Additional
harmonics that are superimposed on the fundamental
frequency are usually whole number multiples of the first
harmonic. The fifth harmonic of a 60 Hz power supply, for
example, is 300 Hz (60 x 5).
A distinct advantage of Siemens MASTERDRIVEs equipped
with AFE and a Clean Power Filter is they are optimally
harmonized with each other to eliminate harmonics and provide
a clean power supply. In addition, the Siemens AFE allows for
capacitive KVAR production which effectively compensates for
other inductive loads in an industrial plant. This helps reduce the
overall utility bill.

82

Compact Units

Compact units require the smallest mounting space. Units can

be DIN-G rail mounted side-by-side without spacing. There are
four sizes: A, B, C, and D. Compact units are available with
ratings from 3 to 50 HP (5.6 to 72 Amps) at 460 VAC.

The following table shows the size in millimeters and maximum

current ratings for compact units.

Size
Depth (mm)
Width (mm)
Height (mm)
P 230V (HP)

90
425
3/5

P 400V (HP)

3 / 5 / 7.5

P 500V (HP)

135
425
5 / 7.5 / 10

180
600
15

7.5 / 10

15 / 20

270
600
15 / 20 / 25
25 / 30 /
40 / 50

3 / 5 / 7.5 /
10 / 15

20

350

20 / 30 / 40

83

Chassis Units

Chassis units can also be mounted side-by-side without

spacing. They are easily mounted on the wall when supplied in
an IP20 enclosure. There are four sizes: E, F, G, and K. Chassis
units are available with ratings from 60 to 500 HP (83.7 to 590
Amps) at 460 VAC.

The following tables show the size in millimeters and maximum

current ratings for the chassis units.
Size
Version
Depth (mm)
Width (mm)
Height (mm)

F
AC / DC
365

270

360
1050

465
508
1450

J
DC / DC

K
AC / DC
565
800

1400

P 400V (HP)

60

75 / 100 /
125

150 / 200 /
250 / 300

300 / 600

P 500V (HP)

50 / 60

75 / 100

125 / 150 /
200 / 250

300 / 400 /
450

75 / 100

120 / 150 /
175 / 210

250 / 335 /
420

P 690V (HP)

Size
Version
Depth (mm)
Width (mm)
Height (mm)
P 400V (HP)
P 500V (HP)
P 690V (HP)

84

1750
300 / 350 /
400 / 500 /
600
300 / 350 /
400 / 450
250 / 335 /
420 / 525 /
600 / 800

M
N
DC / DC
565
2 x 800 +
1100
2 x 800
2 x 1100
508
1750
1000
1200 / 1500
1200
1700
1050 / 1200 1300 / 1450 1300 / 1450 2000 / 2300
1340 / 1600 1750 / 2000 1750 / 2000 2500 / 3000

Cabinet Units

Cabinet units, referred to as 6SE71 for IEC standards or 6SE72

for NEMA standards, are ready-wired complete units for single
and multimotor applications. All components are accessible
from the front of the cabinet. Cabinet units are available with
ratings from 50 to 10,000 HP.

85

Sinewave Filter and

dv/dt Filter

Distance from the drive to the motor must also be taken into
consideration. All motor cables have line-to-line and line-toground capacitance. The longer the cable, the greater the
capacitance. Some types of cables, shielded cable for example,
have greater capacitance. Spikes occur on the output of all
PWM drives because of the charging current of the cable
capacitance. Higher voltage (460 VAC) and higher capacitance
(long cables) result in higher current spikes. Voltage spikes
caused by long cable lengths can potentially shorten the life of
the motor. Spikes are generally the same value regardless of
horsepower, therefore; smaller horsepower motors are more
susceptible to damage.
Various devices are available for the MASTERDRIVE VC to
protect the inverter and motor. A dv/dt filter, for example, limits
motor voltage rise time (dv/dt) and maximum voltage spikes.
This allows cable lengths greater than 300 meters. Another
device designed to protect the motor from high voltage spikes
is a sinewave filter. The sinewave filter generates a sinusoidal
motor voltage and output current. It is very important to fully
understand the chart, which shows the criteria for selecting the
proper output reactor, dv/dt filter, or sinewave filter. If the
guidelines are ignored there will be problems.

86

Internal Layout

The following drawing illustrates the internal layout of a size D

compact unit. The MASTERDRIVE can be controlled via a
keypad and display, referred to as the Parametrization Unit
(PMU). Customer control connections (start/stop, speed
reference, etc.) are made on the control card (CUVC). The
electronics box is equipped with three slots for the CUVC board
and two option boards. The size D compact unit has a
transformer to supply a cooling fan. Smaller units may not have
a supply fan transformer.

87

Programming and
Operating Sources

MASTERDRIVEs can be programmed and operated from

various sources:
Operator Control Panel (OP1S)
Parameterization Unit (PMU)
Terminal strips on the CU board
Serial interface (various)

PMU, OP1S, and HMI Panels

The MASTERDRIVEs can be programmed and operated by the

PMU, OP1S, or other SIMATIC HMI device such as the TP170A
(shown), TP170B, OP27, or MP370.
Parameters, such as ramp times, minimum and maximum
frequencies, and modes of operation are easily set. The
changeover key (P) toggles the display between a parameter
number and the value of the parameter. The up and down
pushbuttons scroll through parameters and are used to select a
parameter value, once the P key sets the parameter. The
OP1S has a numbered key pad for direct entry. The TP170A uses
a touch-sensitive screen for control and monitoring.

Serial communication is available through RS232 or RS485

connections. The OP1S can be mounted directly on the PMU or
up to 200 meters away. An additional 5 volt power supply is
required for remote operation over 5 meters. The TP170A is
powered from the drive and standard PROFIBUS connections.

88

Electronics Box

The electronics box contains the CUVC and option boards. The
CUVC board is plugged into slot 1. The CUVC board is the
central electronic board. It has input and output connections for
wiring the control devices of various functions such as start/
stop pushbuttons and speed potentiometer. The CUVC board is
self-optimizing and has comprehensive diagnostics.
Up to six boards can be installed in the electronics box. An LBA
(Local Bus Adapter) is required if mounting positions 2 or 3 are
needed. In addition, adapter boards (ADB) are necessary for
Slots D and E, and F and G when utilizing the half-size option
boards. A maximum of two communication boards, two
expansion boards, and two encoder boards can be used. Option
boards are automatically recognized by the drive.

89

CUVC Board

90

The Siemens MASTERDRIVE can be programmed and

operated from the terminal strip located on the CUVC board. The
following drawing illustrates a typical terminal arrangement of
the CUVC board used in the MASTERDRIVE VC. RS 485 serial
communication is available on X101. Programmable binary
outputs, used to indicate a condition of the drive, are available
on X101. Binary inputs are also available. Starting/stopping the
drive and selecting preset speeds are examples of possible
binary input functions. The MASTERDRIVE accepts analog
inputs (voltage or current) for speed control on X102. There are
programmable analog outputs for meter indication. A motor
temperature switch can be connected on X103 and is used to
stop a drive in the event a motor becomes overheated.
Connections are also available for a digital tach. Not all features
are available on all versions. Consult detailed product literature
for more information.

Communication Options

Communication option boards CBP2, SLB, SCB1, and SCB2

allow high speed drive-to-drive (peer-to-peer) communication
through RS 485 wires or fiber-optic cables. Peer-to-peer
communication allows data to be exchanged between drives
and is available using serial communication boards SLB, SCB1,
and SCB2, and technology boards T100, T300, and T400. PC and
PLC communication is available with SCB2 (USS Protocol) and
communication board CBP2 (PROFIBUS).
The SLB board is used for peer-to-peer communication with
other drives via SIMOLONK. SIMOLINK is a high speed (11
mbaud) fiber optic ring bus that allows various data to be
passed from one drive to next.

Expansion Boards

Expansion boards are used to expand the number of digital and

analog inputs and outputs. In addition to a 120 volt interface that
is available, EB1 and EB2 are half-sized expansion boards that
provide a number of additional I/O possibilities.
The EB1 board has three digital inputs and four bidirectional
digital I/O. Bidirectional I/O can be configured as a digital input
or output. One of the analog inputs is used as a voltage or
current reference input. Two of the analog inputs can also be
configured as digital inputs.
The EB2 board has two digital inputs, one analog input, and
one analog output. In addition, the EB2 has four relay contacts.
Three of the contacts are normally open (NO) and one of the
contacts can be configured as normally open (NO) or normally
closed (NC). A maximum of two half-sized EB boards can be
used.
I/O

EB1

EB2

120 Volt Interface

Digital Inputs

Bidirectional
Digital I/O

Analog Inputs

Analog Outputs

Relay Outputs

Input for 24 V
Power Supply

91

SCB1

In addition to peer-to-peer drive communication the SCB1 can

interface with one or two SCI boards. SCI boards provide
additional inputs and outputs for drive control. SCI1 has 10
binary inputs, 7 binary outputs, 3 analog inputs, and 3 analog
outputs. SCI2 has 16 binary inputs and 12 binary outputs. Inputs
and outputs on the SCI1 and SCI2 boards provide more isolation
and electromagnetic noise immunity than the standard I/O on
the CU boards. SCI1 or SCI2 boards should be used in
applications where noise immunity is a concern. The SCB2
board does not interface with SCI boards.

Encoder Interfaces

Digital tachometers (encoders) can be used to measure the

actual speed of the motor. The Digital Tachometer Interface (DTI)
is designed to be used with digital tachometers (encoders) that
operate at a voltage other than 11-30 VDC. The DTI is also
required for use with HTL encoders with inverted channel,
floating HTL encoders, TTL encoders, or encoders with cables
greater than 495 feet.

92

SBP Encoder Board

The SBP is another option that can be used to connect a digital

tach to the drive. This option can be used with differential or
frequency control. The SBP can also be used to monitor an
external encoder, such as might be connected to the driven
machine.

Analog Tachometers

Analog tachometers can also be used to measure the actual

motor speed. Analog tachometers generate a DC voltage which
is proportional to the speed. The voltage at maximum speed is a
function of the actual tachometer, and generally lies between 10
V and 300 V. Closed loop speed control with an analog tach can
be applied to a speed range from 1 RPM to 6000 RPM. An
analog tach interface (ATI) board is used to connect an analog
tach to the CUVC board.

93

Technology Boards

Technology boards (T100, T400, and TSY) provide application

specific control and enhancement. It should be noted that
technology boards are not compatible with the optional 120 volt
interface card. Technology option boards can be selected for
sectional drives, synchronized running, winders, and
positioning.
The TSY, for example, allows a drive to synchronize with a
frequency. This is ideal for transferring motors across the line, or
for synchronizing to the output of another drive for transferring
the motor from one drive to another without shutting down a
process.

94

Review 5
1.

The Siemens MASTERDRIVE can be referred to by a

model series number, ____________ .

2.

A MASTERDRIVE configured so that a common bus

supplies power to several AC drives are referred to as
____________ .

3.

____________ ____________ ____________ with a Clean

Power Filter is a braking option that returns braking
energy to the power source and helps to reduce
harmonics.

4.

Compact units are available from 3 to ____________ HP.

5.

Cabinet units are available from ____________ to 10,000

HP.

6.

To help reduce or eliminate voltage spikes that can

occur, a ____________ filter should be used with when
the distance between a 325 V to 575 V MASTERDRIVE
VC and a 1LA5-/1LA6- motor 50 to 100 meters.

7.

The ____________ is the central electronic board.

95

Parameters and Function Blocks

The MASTERDRIVE VC features an extensive parameter set

that can easily be adapted to almost any drive task, from simple
to complex. A wide scope of parameters include:

Automatic Restart Function

Restart on the Fly
Line Synchronization
Synchronization of Several Drives
Various Arithmetic Operations
Acceleration/Deceleration Control

In addition the MASTERDRIVE VC supports a wide range of

motors. A database of characteristics for specific motors is
available, or characteristics for motors not already identified can
be input. The MASTERDRIVE VC also supports ar large database
of faults and alarms. This provides the operator with a clear
indication of what may be needed to correct the problem.
There are literally hundreds of parameters within the
MASTERDRIVE VC. It is beyond the scope of this course to
cover these in any detail. However, it is important to undertand
how parameters and function blocks work together.
Parameters

A parameter is a variable that is given a constant value for a

specific purpose or process. Parameter values are used to
provide instructions to the drive. In the Siemens
MASTERDRIVE VC each parameter is cleary designated by an
assigned number. Parameters are differentiated according to
their function:

96

Function Parameters (can be read and written)

Visualization Parameters (can only be read)
BICO Parameters (can be read and written)

Function Parameters

Acceleration or deceleration times are examples of function

parameters. P462 and P463, for example, work together to
instruct the MASTERDRIVE how much acceleration time is
needed to accelerate the motor from 0 to 100% speed. P462
can be set to any value between 0.0 to 999.9. P463 can be set
for 0, 1, or 2. If P462 were set to 30.00 and P463 were set to 0,
then the drive would take 30 seconds to accelerate the motor
from 0 to 100% speed.

Visualization Parameters

Visualization parameters are used for visualizing internal

quantities. These parameters can are only displayed and cannot
be changed by the operator. Visualization parameters are
distinguished by a lower case r
. Parameter r002, for example,
displays the value of voltage output to the motor.

Function Blocks

A function block consists of several parameters grouped

together to perform a specific task. The following function block
represents one example of how a proportional/integral (PI)
controller can be used in speed control of a MASTERDRIVE.

97

Function Parameters

The response of a function block is determined by function

parameters. Proportional gain and integral time, for example,
determine the response of a PI-controller. Each parameter has a
name, identifying number, value range, and a factory setting.
Function parameters can be indexed.

Indexing and Data Sets

In many applications it may be desirable to configure the

MASTERDRIVE for variations in operation. For example, there
may be a situation in an application where it is desirable to have
different acceleration times. Indexed parameters can have up to
four different values stored with them. Each value stored is part
of a data set. Parameter P462, acceleration time, is an example
of indexed parameter. P462 can have four different acceleration
times stored. P462 could, for example, have the following
values:
P462.1 = 0.50
P462.2 = 1.00
P462.3 = 3.00
P462.4 = 8.00
If data set 1 is active, the acceleration time is 0.50 seconds. If
data set 2 is active, the acceleration time is 1.00 second. Data
sets are operator selected and can be changed at any time.

98

PI-Controller

PI-controllers are commonly used in drive technology. In our

example the desired speed and actual speed are input to a
summation point. The two signals are opposite in polarity.
When the actual speed is equal to the desired speed the
deviation, which is input into the PI-controller, is zero (0).
Whenever desired speed and actual speed are different there is
a deviation.
Changes in load on the motor, for example, can affect motor
speed. A sudden increase in load would cause the motor to
slow down. This would decrease the feedback from actual
speed and the deviation would become more positive. It is also
possible that the application may require the motor to slow
down or speed up. Until the motor reaches the new desired
speed there will be a deviation.

The PI-controllers job is to make speed corrections quickly a

minimal amount of overshoot and oscillation. Parameter P235
(gain) and parameter P240 (time) are used to tune the PIcontrollers performance. The end result should be a fast
response time with about a 43% initial overshoot. The motor
should then settle in to the new desired speed.

99

Connectors and Binectors

Connectors and binectors are elements used to exchange

signals between function blocks. Connectors are used to store
analog values. Analog values are stored in the form that is
represented by 16 bit or 32 bit words. Binectors are used to
store binary (digital) information.

Connectors and binectors are identified by a name and number.

Connectors with 16 bit resolution are identified with a K.
Connectors with 32 bit resolution are identified with a KK
.
Binectors are identified with a B.

100

BICO Parameters

BICO is the term used to describe the method of connecting

function blocks together. This is performed with BInectors and
COnnectors. A connection between two function blocks
consists of a connector or binector and a BICO parameter. With
BICO parameters you can determine the sources of the input
signals of a function block. This allows the user to softwire
function blocks to meet specific application requirements.

101

Applications

When applying an AC drive and motor to an application it is

necessary to know the horsepower, torque, and speed
characteristics of the load. The following chart shows typical
characteristics of various loads.

Loads generally fall into one of three categories:

Constant Torque

The load is essentially the same

throughout the speed range. Hoisting
gear and belt conveyors are examples.

Variable Torque

The load increases as speed increases.

Pumps and fans are examples.

Constant Horsepower The load decreases as speed

increases. Winders and rotary cutting
machines are examples.

102

Constant Torque Applications

A constant torque load implies that the torque required to keep

the load running is the same throughout the speed range. It
must be remembered that constant torque refers to the motors
ability to maintain constant flux (). Torque produced will vary
with the required load. Peak torques in excess of 100% can
occur at any speed, including zero speed. One example of a
constant torque load is a conveyor similar to the one shown
below. Conveyors can be found in all sorts of applications and
environments, and can take many styles and shapes.

103

Conveyors are made up of belts to support the load, various

pulleys to support the belt, maintain tension, and change belt
direction, and idlers to support the belt and load.

Motor Speed

The speed and horsepower of an application must be known

when selecting a motor and drive. Given the velocity in feet per
minute (FPM) of the conveyor belt, the diameter in inches of the
driven pulley, and the gear ratio (G) between the motor and
driven pulley, the speed of the motor can be determined. The
following formula is used to calculate conveyor speed.

If, for example, the maximum desired speed of a conveyor is

750 FPM, the driven pulley is 18 in diameter, and the gear ratio
between the motor and driven pulley is 4:1, the maximum
speed of the motor is 638.3 RPM. It would be difficult to find a
motor that would operate at exactly this speed. An AC drive can
be used with an eight-pole motor (900 RPM). This would allow
the conveyor to be operated at any speed between zero and the
desired maximum speed of 750 FPM.

104

Another advantage to using AC drives on a conveyor is the

ability to run different sections of the conveyor at different
speeds. A bottle machine, for example, may have bottles
bunched close together for filling and then spread out for
labeling. Two motors and two drives would be required. One
motor would run the filling section at a given speed and a
second motor would run the labeling section slightly faster
spreading the bottles out.

Horsepower

Calculating motor horsepower is complicated with many

variables, which is beyond the scope of this course. Someone
with knowledge of, and experience with conveyor operation
would be required to accurately calculate the required
horsepower. The horsepower required to drive a conveyor is the
effective tension (Te) times the velocity (V) of the belt in feet per
minute, divided by 33,000.

Effective tension (Te) is determined by several forces:

Gravitational weight of the load

Length and weight of belt
Friction of material on the conveyor
Friction of all drive components and accessories
- pulley inertia
- belt/chain weight
- motor inertia
- friction of plows
- friction of idlers
Acceleration force when new material is added to
conveyor

105

If the effective tension of a conveyor were calculated to be 2000

pounds and the maximum speed is 750 FPM, then the required
horsepower is 45.5.

Starting torque of a conveyor can be 1.5 to 2 times full load

torque. A motor capable of driving a fully loaded conveyor may
not be able to start and accelerate the conveyor up to speed. AC
drives can typically supply 1.5 times full load torque for starting.
An engineer may need to choose a larger motor and drive in
order to start and accelerate the conveyor.
Torque, HP, and Speed

106

The speed on a conveyor is increased by increasing the AC

drive frequency (F) to the motor. Torque (T) is affected by flux ()
and working current (IW). The drive will maintain constant flux by
keeping the voltage and frequency ratio constant. To do this the
drive increases voltage and frequency in proportion. During
acceleration working current will increase, however, causing a
corresponding increase in torque. Once at its new speed the
working current and torque will be the same as its old speed.
The conveyor cannot be operated above the rated frequency of
the motor (60 Hz) without losing available torque. Since torque
is proportional to (volts/Hz)2 any increase in speed will cause
available torque to decrease by the square. As a result, the
motor will be unable to supply rated torque. Horsepower (HP) is
affected by torque and speed. There will be a corresponding
increase in horsepower as speed (RPM) increases.

Variable Torque Applications

A variable torque load implies that torque and horsepower

increase with an increase in speed. Overloads, as a rule of
thumb, are not possible at lower speeds. Peak torques are
typically limited to rated torque. Fans and pumps are examples
of variable torque. A pump used on a chilled water system is
shown below.

107

Variable Torque Pumps

There are several types of pumps. The most common pump is

the end-suction centrifugal pump illustrated below. There are
variations of the centrifugal pump. Turbine and propeller pumps
are examples. This section deals with variable torque loads. The
faster a centrifugal pump turns, the more fluid it pumps and the
more torque it requires. It should be noted that not all pumps
are variable torque. Reciprocating, positive displacement
pumps are constant torque.

Horsepower

Calculating horsepower for a pump application is an involved

process that requires someone with a thorough knowledge of
the application and pumps. The following information is for
illustration only. There are three related horsepower calculations
involved in pump applications: liquid, mechanical and electrical.

Hydraulic Head

Hydraulic head is the difference in hydraulic pressure between

two points, which actually includes elevation, pressure and
velocity. An increase in pump speed would cause increases in
pressure and velocity which increases the hydraulic head.

108

Liquid Horsepower

Liquid horsepower is the hydraulic power transferred to the

pumped liquid. The following formula can be used to calculate
liquid energy.
Liquid Energy in ft-lb = Total Head x (Gallons x Weight)
Water weighs 8.34 pounds per gallon. If 50 gallons of water per
minute were required to be moved through 100 feet of head the
energy required would be 41,700 ft-lb/minute.
100 feet x (50 gallons x 8.34) = 41,700 ft-lb/minute
If the pumps speed were increased so that 100 gallons of water
were being pumped through 100 feet of head the energy would
be 83,400 ft-lb/minute. Twice the energy would be required. The
hydraulic head would, in actuality, also increase.
100 feet x (100 gallons x 8.34) = 83,400 ft-lb/minute
The common method of expression is horsepower. One
horsepower is equal to 33,000 ft-lb/minute.
Therefore, 41,700 ft-lb/minute is 1.26 HP and 83,400 ft-lb/minute
is 2.53 HP.

Mechanical Horsepower

Mechanical horsepower is the horsepower input to the pump

and is equal to the liquid horsepower divided by the pumps
efficiency. If the liquid horsepower is 2.53 and the pump is 75%
efficient the brake horsepower is 3.4 HP.

Electrical Horsepower

Electrical horsepower is the horsepower required to run the

motor driving the pump and is equal to the mechanical
horsepower divided by the motors efficiency. If the motor is
90% efficient the electrical horsepower is 3.78 HP. It can be
seen that with an increase of pump speed there is a
corresponding increase in electrical horsepower.

109

Torque, HP, and Speed

The speed on a pump is increased by increasing the AC drive

frequency (F) to the motor. Torque (T) is affected by flux () and
working current (IW). The drive will maintain appropriate flux by
adjusting the voltage and frequency ratio dependent on speed.
During acceleration, working current will increase causing a
corresponding increase in torque. In this application, torque
increases in proportion to the speed squared. This is due to the
increase in hydraulic head as the pump works harder to pump
more fluid. Horsepower increases in proportion to the speed
cubed due to an increase of torque and speed. The pump
cannot be operated above the rated frequency of the motor (60
Hz) because the drive will no longer be able to provide constant
flux. As a result, the motor will be unable to supply rated torque.
The loads torque requirements increase while the motors
ability to supply torque decreases.

Fans

This same principle applies to fan applications. The horsepower

of a fan is determined by dividing the product of air flow (in
cubic feet per minute) and pressure by the product of the
constant 6356 and fan efficiency. Increasing the speed of the
fan increases air flow and pressure, requiring the motor to work
harder (IW increases). Torque and horsepower increase.

110

Constant Horsepower Applications

Constant horsepower applications require a constant force

as radius changes. A lathe, for example, starts out with a certain
diameter object. As the object is cut and shaped the diameter is
reduced. The cutting force must remain constant. Another
example of a constant horsepower application is a winder
where radius increases as material is added to a roll and
decreases as material is removed.

Relationship of Speed,
Torque, and Horsepower

Applications, such as lathes, that are driven in a continuous

circular motion are sometimes referred to as spindle drives.
Horsepower will remain constant in a spindle drive application.
The surface speed in feet per minute (FPM) is equal to 2 times
the radius (in feet) of the material times the speed in RPM.
Surface speed will remain constant as the material is shaped
and the radius reduced. Torque is equal to force times radius.
Horsepower is equal to torque times speed.

Surface Speed (FPM) = 2 x Radius x Speed (RPM)

Torque = Force x Radius
HP = Torque x Speed
111

The drive increases the speed (RPM) of the material as the

radius is reduced. If the cutting tool has cut away half of the
radius, for example, the RPM must double to maintain a
constant surface speed (FPM). Reducing the radius by half will
cause a corresponding reduction in torque. A doubling of speed
(RPM) and a reduction of torque by half causes horsepower to
remain constant.

A smaller radius requires less torque to turn. Because torque

decreases with a smaller radius, motors operating a constant
horsepower application can be run above base speed. A 60 Hz
motor, for example, could be run at 90 Hz when the radius is at
minimum. RPM must increase to keep surface speed constant.
An increase of speed (RPM) and a decrease in torque means
horsepower will remain constant.

112

Multimotor Applications

Many applications require more than one motor. In some

instances, one drive can supply two or more motors. When this
happens, the current rating of the motors added together cannot
be greater than the current rating of the drive. Other applications
require multiple motors and drives. A spinning machine for
producing synthetic fibers, illustrated below, is one example of
a multimotor, multidrive application. Various motors run the
extruder, spinning pumps, preparation rolls, godets, traversing
devices and winders. One drive may supply all the spinning
pump motors or all the godet motors or individual motor control
for each pump or godet may be used.

113

Review 6
1.

Parameters that can be read only are referred to as

____________ parameters.

2.

A function block consists of several ____________

grouped together to perform a specific task.

3.

____________ is the term used to describe the method

of connecting function blocks together.

4.

An application, such as a conveyor, where the torque

remains essentially the same throughout the speed
range is referred to as ____________ torque.

5.

Operating a motor above base frequency causes the

motors ability to produce torque to ____________ .
a. increase

114

b.

decrease

6.

Fans and pumps are examples of ____________ torque

applications.

7.

Identify the category of the following speed, torque, and

horsepower graphs.

Review Answers

Review 1

1) force; 2) 15; 3) torque; 4) 80; 5) inertia; 6) Speed;

7) revolutions per minute

Review 2

1) 5; 2) 1.15; 3) 49.6; 4) 120; 5) 1800, 1500; 6) increase;

7) decrease; 8) Slip

Review 3

1) 7.67; 2) increase, increase; 3) b; 4) horsepower; 5) SIMOVERT;

6) 650; 7) c; 8) d; 9) a

Review 4

1) P; 2) 650; 3) b; 4) d; 5) II; 6) MMJ110; 7); 3 to 5

Review 5

1) 6SE70; 2) DC - AC; 3) Active Front End; 4) 50; 5) 50; 6) dv/dt;

7) CUVC

Review 6

1); visualization; 2) parameters; 3) BICO; 4) constant; 5) b;

6) variable; 7) constant torque, constant horsepower, variable
torque

115

Final Exam

The final exam is intended to be a learning tool. The book may

be used during the exam. After completing the test, mail the
tear-out answer sheet in for grading. A grade of 70% or better is
passing. Upon successful completion of the test a certificate
will be issued.
1.

____________ is a twisting or turning force that causes an

object to rotate.
a. Torque
b. Friction

2.

c.
d.

power
energy

c.
d.

65
120

Magnetic lines of flux () in an AC motor are

proportional to ____________ .
a.
b.
c.
d.

116

47
150

A motor with a rating of 60 KW would have an equivalent

rating of ____________ HP.
a. 45
b. 80

5.

c.
d.

The rate of doing work is called ____________ .

a. inertia
b. speed

4.

Inertia
Acceleration

If 50 pounds of force were applied to a lever 3 feet long,

the torque would be ____________ lb-ft.
a. 16.7
b. 53

3.

c.
d.

voltage divided by frequency

frequency divided by voltage
rotor speed divided by synchronous speed
synchronous speed divided by rotor speed

6.

A four-pole motor operating at 50 Hz has a synchronous

speed of ____________ RPM.
a. 1500
b. 3000

7.

c.
d.

5.5
20

The most common and most suitable NEMA design motor

for use on AC drives is NEMA ____________ .
a. A
b. B

9.

1800
3600

A motor with a synchronous speed of 900 RPM and a rotor

speed of 850 RPM has ____________ % slip.
a. 3
b. 9.4

8.

c.
d.

c.
d.

C
D

____________ torque is also referred to as starting torque.

a. Pull up
b. Accelerating

c.
d.

Breakdown
Locked rotor

10. A NEMA B motor that is started by connecting it to the

power supply at rated voltage and frequency has a typical
starting current of ____________ %.
a. 100
b. 150
11.

c.
d.

200
600

The temperature rise of a motor with Class F insulation is

____________ C with a 10 C hot spot.
a. 60
b. 105

c.
d.

80
125

12. The volts per hertz ratio of a 460 VAC, 60 Hz motor is

____________ V/Hz.
a. 3.8
b. 7.67

c.
d.

5.1
9.2

13. A motor operated within a speed range that allows a

constant volts per hertz ratio is said to be ____________ .
a. constant hp
b. variable torque

c.
d.

constant torque
variable flux

117

14. The section of an AC drive that controls output voltage and

frequency to an AC motor is the ____________ .
a. converter
b. DC link

c.
d.

inverter
L1 choke

15. Frame size C, 480 volt, MICROMASTER 420 drives are

available with power ratings from ____________ to
____________ horsepower.
a. 1/2 to 2
b. 7.5 to 15

c.
d.

3 to 50
60 to 500

16. To get four-quadrant operation with a Siemens

MICROMASTER an optional ____________ must be used.
a.
b.
c.
d.
17.

____________, in conjunction with a Clean Power Filter,

provides regenerative control and reduces harmonics.
a.
b.
c.
d.

18.

DC injection brake
converter bridge
4-digit LED display
braking resistor

Active Front End

Rectifier Regenerative Front End
6-Pulse Converter
12-Pulse Converter

____________ is the term used with the Siemens

MASTERDRIVE VC to describe the method of connecting
function blocks together.
a. AFE
b. Binector

c.
d.

BICO
SBP

19. A centrifugal pump is a ____________ application.

a.
b.
c.
d.

118

constant torque
constant flux
constant HP
variable torque

20. If a conveyor has an effective tension (TE) of 1000 pounds,

and a maximum speed of 100 FPM, the required
horsepower is ___________ HP.
a. 3
b. 25

c.
d.

10
45

119

Notes

120