Advanced Motor Theory

16th December - 2023

Mina Sidhom
Sr Sales Development Manager -
Grundfos Saudi
[email protected]
Agenda

• Electrical motor basics and it output power

• Standards for AC motors

• IEC Standard Vs. NEMA Standard

• Motor protection

• Starting methods

• Motor Maintenance
Some basic motor concepts
Some basic motor concepts
Some basic motor concepts
Some basic motor concepts
Today’s Scope

Asynchronous AC Induction Squirrel Cage Motor

Induction Motor Basics
Magnetism
Electromagnetism
Alternating current

• An electrical current that reverses in

intervals

• Has alternating positive and negative

values
Stages of Movement
Induction
Electromagnetic Induction
Induced voltage
Electromagnets Arrangement
Motor speed, torque and power
Synchronous speed

• Motors are called Asynchronous because

the speed of rotor magnetic field and
stator magnetic field are not synchronized
or same
No of Synchronous Synchronous Speed
poles Speed (at 50 Hz) (at 60 Hz)
2 3000 3600
4 1500 1800
120 . 𝐹𝐹 6 1000 1200
Ns=
𝑃𝑃 8 750 900
10 600 720
12 500 600
Slip

• The difference between Magnetic

Synchronous speed and real rotor speed

𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 − 𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆

𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 = . 100
𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠
Motor Nameplate

• Calculate the slip % of this motor at rated speed

Linear Power

• The rotor current is induced via the power

supply connected to the motor

• It is possible to calculate the power input

when we know the details about the
motor’s power supply
Motor Torque

• Torque is a turning or twisting force which

makes a given object rotate. For example,
when a force is applied to the end of a
shaft, this creates a turning effect or
torque at the pivot point

Torque = Force x Radius (T = F • r)

Power = T ・ ω
Speed Vs torque
Poles of Motor

No of Synchronous Synchronous Speed

poles Speed (at 50 Hz) (at 60 Hz)
2 3000 3600
4 1500 1800
6 1000 1200
8 750 900
10 600 720
12 500 600
Torque calculation
Calculate the torque generated by these two motors
Components of motor
International Standards for AC motors
Overveiw

National Electrical Manufacturers Association International Electrotechnical Commission

NEMA MG1 IEC 60034
IEC 60034
Intl standard IEC Description
IEC 60034-1+ A1 and A2 Part 1: Rating and design.
IEC 60034-2 Part 2: Measuring methods to determine the loss and the efficiency of electric motors
IEC 60034-5 Part 5: Enclosure class for rotating electric motors
IEC 60034-6 Part 6: Cooling (IC code)
IEC 60034-7 + A1 Part 7: Classification of types of construction and mounting
IEC 60034-8 Part 8: Terminal marking and direction of rotation
IEC 60034-9 Part 9: Noise limits
IEC 60034-11 Thermal protection
IEC 60034-12 Part 12: Start capacity of 3-phase induction motors
IEC 60034-14 Part 14: Mechanic vibration for machines
IEC 60038 IEC standard voltages.
IEC 60072-1 Dimensions and output power for rotating electric motors
IEC 62114 Electrical insulation systems - Thermal classification
EN 50102 (No IEC) Degrees of protection for enclosures for electrical equipment against external mechanic strokes (IK-code).
DIN 51825 Lubricant; lubricating grease K; classification and requirements (1990-08)
DIN 44082 Thermistors; PTC sensors; thermal protection of machines climate categorization HFF (1985-06).
EN ISO 2409 Paints and enamels. Grid cut value (adhesion)
EN ISO 3743-2 / EN ISO Standards Related to Measuring, testing and verification Noise from Machine
4871 / EN ISO 11203
IEC 60034-1 - Rotating duty cycles and ratings

• The IEC 60034-1 standard recognises ten

duty types

• Most motors run continuously at constant

load

• In some cases the motor has to operate for

shorter periods of time or intermittently
IEC 60034-1 - Electrical tolerances

• Voltage and frequency variations during

operation

• A motor shall be capable of performing its

primary function in zone A

• But need not comply fully with its

performance at rated voltage and
frequency and may exhibit some
deviations

• Temperature rises may be higher than at

rated voltage and frequency if operating at
the perimeter of zone A

• Extended operation at the perimeter of

zone B is not recommended

• Motors capable to operate at Zone B will

have more life time if operated on rated
IEC 60034-1 - Electrical tolerances

• High-voltage test
• The aim of the high-voltage test is to
test the adequacy of the insulation

• The test is carried out by supplying a

high voltage between all phases and
the frame and the leakage current is
then measured

1000 V + 2 • Urated for 1 minute

• For mass production, time can be

reduced by increasing applied voltage

• Ground test
• Measuring Resistance between frame
and ground terminal and shall not be
more the 0.1Ω
Characteristics of motors - voltage & frequency

Rated voltage variation Rated frequency variation

IEC versus NEMA motor standards

Parameter IEC NEMA

Power : kW (Kilo Watts) HP (Horse power)

Zone A: ± 5%
Voltage tolerance : ± 10%
Zone B: ± 10%
Zone A: ± 2%
Frequency tolerance : ± 5%
Zone B: +3/ -5%

Service factor : Not recognized Recognized

Efficiency classes : IE1-IE5 Energy efficient, Premium, Super premium eff.

Terminal box : On the Top (standard) On the left side (seen from shaft end)

Frame size : In mm In Inches

Mounting positions : Example: IM 3601 Example: IM B14
IEC 60034-2 - Efficiency standards

• This standard is intended to establish methods of

determining efficiencies from tests, and also to
specify methods of obtaining specific losses

𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑜𝑜𝑜𝑜𝑜𝑜 𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 𝑎𝑎𝑎𝑎𝑎𝑎 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙

ɳ = 1−
𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑖𝑖𝑖𝑖 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 𝑖𝑖𝑖𝑖

1. Stator winding loss Pcu1≈ 40-45%

2. Rotor winding loss Pcu2≈ 15%
3. Friction loss Pfric≈ 10-15%
4. Iron loss Pfe≈ 20%
5. Stray loss Pstray≈ 10%
IEC 60034-2 - Efficiency standards

Direct method of analyzing motors

• The most common method used for

testing small scale motors < 45 kW

• The power output is measured by means

of a torque transducer

2 . 𝛱𝛱 . 𝑛𝑛
𝑃𝑃2 = 𝑡𝑡. ω = 𝑡𝑡 .
60

𝑃𝑃2
ɳ= %
𝑃𝑃1
 IEC 60034-2 - Efficiency standards

Indirect method for analyzing motors

• Only Used for Three phase motors

• No torque transducers used

• All possible losses are calculated

1. Stator winding loss Pcu1

2. Rotor winding loss Pcu2
3. Friction loss Pfric
4. Iron loss Pfe
5. Stray loss Pstray

𝑃𝑃2 𝑃𝑃1 − Σ𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿 𝑃𝑃1– 𝑃𝑃𝑃𝑃𝑃𝑃1– 𝑃𝑃𝑃𝑃𝑢𝑢𝑢– 𝑃𝑃𝑃𝑃𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡– 𝑃𝑃𝑃𝑃𝑃𝑃– 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃

ɳ= = = %
𝑃𝑃1 𝑃𝑃1 𝑃𝑃1
IEC 60034-30-2 - Efficiency Classes (IE Code)

• IEC TS 60034-30-2:2016(E) specifies efficiency classes for variable speed rotating electric
machines which is not covered in IEC 60034-30-1.

• Permanent Magnet Synchronous Motors (PMSM) are good example

Variables on Which Efficiency Differs

• KW
• Number of poles
• Frequency
• Voltage
IEC 60034-5
Degrees of protection of electrical equipment (IP code)
First Digit Second Digit
(Protection against Dust/solids) (Protection against water)
0 None 0 None
Vertically falling drops of water,
1 > 55 mm, e.g. a hand 1
such as condensed water
Vertically falling drops of water,
2 > 12 mm, e.g. a finger 2
from an angle of 15°
Water spray falling at an angle of
3 > 2.5 mm,i.e. wires, tools, etc. 3
60°
4 > 1 mm,e.g. wires 4 Water splashing from any direction
Water projected from a nozzle
5 Dust ingress 5
from any direction
Heavy seas or high-pressure water
6 Completely dust-proof 6
jets from any direction
When submerged from 15 cm to 1
7 m in water for a period specified by
the manufacturer
Continuous submersion in water
8 under conditions specified by the
manufacturer
IEC 60034-6
Methods of cooling of electric motors (IC code)
• IC 410 : The motor is cooled by free
convection

• IC 411 : The motor is cooled by a fan

mounted on the motor shaft.

• IC 418: The motor is cooled by an air flow

typically coming from an external fan.
IEC 60072
Dimensions and output series
IEC 60072
Frame Sizes and KW
IEC 60034-7
Mounting arrangements and types of construction

Foot Motor with Motor with Combination of

mounted tapped-hole free-hole flange
motor – B3 flange – B14/V18 flange – B5/V1 and foot – B35
Motor Name plate and Voltages
Star(Y) or Delta(Δ) Connections of Motor

Star(Y) Delta(Δ)
IEC 60034-14
Permitted maximum vibration limits for electric motors
• The permitted vibration limits for electric
motors are stated in IEC 60034-14
IEC 62114
Electrical insulation systems - Thermal classification
• Electrical insulation system for Insulation Class
wires inside motor
• Internal temperature rise A E B F H
• Ambient temperature
105 120 130 155 180 oC
Thermal
15
Margin/Hot spot

10
10
Permissible
5
125 temperature
5
105 rise
80
75
60
Maximum
ambient
40 40 40 40 40
temperature
Motor derating- temperature & altitude

Maximum ambient temperature of 40 °C and at a maximum altitude of 1000 meters

above sea level.
IEC 62114
Electrical insulation systems - Thermal classification
Markings and Approvals
Motor protection
Motor protection
What kind of possible faults?
• Problems with the power supply quality:
• Over voltage
• Under voltage
• Imbalanced voltages/currents
• Frequency variation
• Installation, supply & motor failures
• Slowly developing temperature rise:
• Insufficient cooling
• High ambient temperature
• High altitude operation
• High liquid temperature
• Too high viscosity of the pumping liquid
• Frequent starts
• Too big load inertia (not common for pumps)
• Quickly developing temperature rises:
• Locked rotor
• Phase breakage
Motor protection
Why is motor protection necessary?
• External protection against short circuit in
the whole installation

• External protection against overload of

specific equipment

• Built-in motor protection

Overload accounts for 30% of all

motor failure Source
Electrical Research Association
USA
Motor protection
Fusible safety switch
• Fuse protect against overcurrent

• Manually opens and closes the circuit

• “Quick-acting” fuses Non time-delay fuses

provide excellent short circuit protection
However, brief overloads, such as motor
starting currents, may cause problems for
this kind of fuse

• “Time-lag” fuses provides both overload

and short-circuit protection, Usually they
allow up to 5 times the rated current for
up to 10 seconds and for shorter periods
even higher currents
Time Current Characteristic Curve

The larger the overload, the faster

the protection device will clear the
overload. This is what is known as an
“inverse time-curve.”
Motor protection
Circuit breaker
• A circuit breaker is an overcurrent
protection device

• It opens and closes a circuit automatically

at a predetermined overcurrent

• Opening and closing the circuit breaker

does not damage it

• The circuit breaker is simply reset after the

fault is corrected

• Thermal circuit breakers

• Magnetic circuit breakers

• Thermal - Magnetic circuit breakers

Motor protection
Circuit breaker

Thermal Magnetic
• Temperature sensitive • Not temperature sensitive
• Not voltage sensitive • Voltage sensitive
• Fixed time delay • Various time delays
• Push-to-reset and switch function • Switch function
• Limited circuit functions • Variety of circuit functions
• Small package size • Larger package size
• Lower cost • Higher cost
Motor protection
Circuit breaker - Trip class designation
• Trip time is the time it takes for a relay to
trip during overload

• The most common trip classes are 10, 20

and 30

• Trip class 10 is the most common one for

IEC motors because they are often adapted
to the application

• NEMA motors are applied with more built-

in excess capacity, and therefore, the trip
class 20 is most common
Motor protection
Fuse and Overload Coordination
Motor protection
Advanced external motor protection relays
• More advanced External Protection
Systems provide all protections in one unit

• Perfect for critical operation motors

• Give an alarm before damage results

from a process malfunction
• Diagnose problems after a fault
• Allow verification of correct relay
operation during routine maintenance
• Monitor bearings for temperature and
vibration
Motor protection
Internal protection - built into the motor
• Incase the overload relay does not register
a motor overload

• If the motor is covered and is slowly

warmed up to a high damaging
temperature.
• In general, high ambient temperature.
• If the external motor protection is set at a
too high trip current or is installed in a
wrong way.
• If a motor, within a short period of time, is
restarted several times, the locked rotor
current warms up the motor and
eventually damages it.
Motor protection
Thermal switch - built into the windings
• TN is typically around 150 - 160°C and
usually based on insulation class
Motor protection
PT100 – temperature sensor
• Highly sophisticated Motor internal
temperature monitoring and protecting
device

• Measure exact temperature

• Needs microprocessor based control to

monitor and react

• Recommended for critical machines

Starting methods

But why?
Starting methods

• Voltage transients associated with the

start-up of large motors

• Inrush current, starting current, or locked-

rotor current

• very large current – five to ten times the

full-load current – flows initially

• Starting methods design to reduces

starting current
Starting methods

• DOL

• Star Delta

• Soft Starter

• Variable Frequency Drive

• And many more……

Starting methods
Direct On line - DOL
Starting methods
Star-Delta (SD)
Motor Name plate and Voltages
Starting methods
DOL VS SD
Starting methods
Soft starting
Starting methods
Frequency converter starting
Starting methods
Output filters for frequency converters
Starting methods
Output filters for frequency converters
• An output filter introduces a voltage loss
(voltage drop across the reactors) between
the frequency converter and the motor

• Output voltage of a frequency converter

can never exceed the input voltage

• Installing an output filter will always affect

the overall efficiency of the system

• Required for Longer Distances

Starting methods
Bearing currents
• Usually occurs for motors Above 45 KW

• Reasons to current Induction or rotor:

• Asymmetries in the inverter voltage
• Incorrect cable length
• Improper grounding

• Constant passage of bearing current cause

fluting

• Outer and inner ring and will accelerate

the wear of the bearing with reduced life
as a result
Starting methods
Motors with Insulated Bearings

Motor frame size Cable length Insulated bearings Sine wave filter

< 225 frame < 25m Not required Not required

Recommended for standard motor. Not

< 225 frame > 25m Not required required for inverter duty motor (IEC
60034-25)

> 225 frame < 25m Recommended Not required

Recommended for standard motor. Not

> 225 frame > 25m Recommended required for inverter duty motor (IEC
60034-25)
Starting methods
Comparison

DOL Star- Delta Soft Starter VFD

Cost + ++ +++ ++++

Starting current Upto 10 x Ir 2 to 3 x Ir 4 to 5 x Ir Equal to Ir

High during
Voltage dip High Low Low
transition
Power factor Low Low Low High
2-3 times more
Number of starts Restricted Limited High
than DOL

Thermal stress Very high High Moderate Low

Mechanical shocks Very high Moderate Moderate Low

Motor Maintenance
Motor Maintenance

• Preventive maintenance

• Predictive maintenance

• Reactive maintenance
Motor Maintenance
Preventive maintenance
• Motor ventilation

• Loose connections

• Voltage and current imbalance

• Undervoltage and overvoltage

• Bearings and Its lubrication

Motor Maintenance
Predictive maintenance
• Bearing considerations

• Insulation considerations

• Ground insulation test

• Polarization index tests

• Surge tests

• High potential testing

• Motor temperature

• Thermographic inspection
Motor Maintenance
Reactive maintenance
• When to repair instead of replacing
• New purchase price >< Cost of repair
• Efficiency of existing motor >< efficiency of new motor
• Availability of a new motor
• Lifetime calculations of electric energy consumption
• Cost downtime and repairs

• How to ensure high quality repair work

• Evaluate potential motor repair suppliers

• Be realistic about the repair time
• Let your supplier know what your needs are
Motor Maintenance
Reactive maintenance
 Question & Answers

Mina Sidhom
Senior Sales Development Manager – Grundfos Saudi