Precautions to yield high efficiencies in Inverter duty motors during the life cycle

A.V.Bhalerao, Chief Technology Officer Motors & Drives

CIIs 10th Energy Efficiency Summit , Hyderabad 27th Aug. 2011

National Standard for Energy Efficient Motors

IS 12615: 2004 (First Revision) Energy Efficient Induction Motors Three Phase Squirrel Cage
IS 12615 covers Energy Efficient motors from 0.37kW to 160kW (up to Fr. 315L) IS 12615 specifies two efficiency levels : - eff2 and eff1

IS 12615: 2011 (Second Revision) ( Under printing now)

The new revision is in line with IEC 60034-30 Efficiency classes of single speed 3 phase cage induction motors . Defines efficiency classes IE1, IE2 and IE3. Range covered now upto 375 kW Testing as per IEC 60034-2-1 IE1 and IE2 : Slightly lower than eff2 and eff1 (to compensate for new testing method in which stray losses are higher)

Comparison of eff & IE classes

Output eff2 IE1 eff1 IE2 IE3 IE4

5.5kW 4P

85.7

84.7

89.2

88.2

89.9

91.3

11kW 4P

88.4

87.6

91.0

90.2

91.7

92.9

Why is the Energy Efficient motor more expensive?

eff1 motors are generally priced 5 - 15 % higher than eff2 motors More laminations - longer core length and/or High Grade (low loss) laminations More Copper

Rs

Energy Efficient Motors- Speed and Starting current

Due to reduced rotor losses, speed is higher.(5-15rpm) The driven equipment ( fan / pump ) should be designed accordingly

Due to reduced rotor and stator resistance, starting current is higher. This can go to 700 % in eff1 motors. When used with a VVVF drive, this does not matter as the drive takes care. In other cases, this should be taken care during system design.

Bharat Bijlee Range of eff1 & eff2 motors.

eff2 and eff1 motors are offered by Bharat Bijlee ex-stock Bharat Bijlee also offers a complete range of eff1 customised motors orders with a lead time of 8 weeks Bharat Bijlee does not manufacture motors of efficiency class less than eff2

Energy Efficient Motors for Hazardous Areas

BBL has standard catalogued energy efficient series motors for use in hazardous areas Type MD Type MJ Type ME Type MI Type MN Type MS Flameproof Ex(d) eff2 Flameproof Ex(d) eff1 Increased Safety Ex(e) eff2 Increased Safety Ex(e) eff1 Non Sparking Ex(n) eff2 Non Sparking Ex(n) eff1

Growth in Eff1 motors business

Year 2007 - 08 2008 - 09 2009 -10 2010 -11

available Ex stock. Customer awareness and interest.

% Eff1 to std kW Value 4.6 4.3 14 12.5 21 18 25.3 21

Availability of the complete range of Energy Efficient motors , popular ratings

Advantages of VFD fed motors

Good & precise speed control in required speed range Adjust the speed of the motor and keep it constant under variable system parameters Controls starting current of motor without affecting the torques of the motor & reduces starting losses Less power consumed for fans/ pump applications by operating at low speeds instead of throttling / damper use.

Speed Control

Limiting starting current

Power Saving

Adverse effects of VFD supply

Additional heat generation Since the waveform is not a sine wave and contains harmonics, additional heat is generated in the windings PWM, IGBT devices operate at very high frequencies (2kHz to 15kHz)and have very short rise times leading to high dv/dt. This stresses the insulation, especially the first coil High frequencies of the stator induce shaft voltages in the rotor . This can cause current through the bearing if the voltage is high ( > 500 mV) This current passes through bearings and causes pitting and subsequent early failure of the bearings Motor noise levels are slightly higher due to the high frequencies and rapid voltage changes

High stresses on insulation

Shaft induced voltages and bearing failures

Increase in noise level

Types of additional voltage stresses

Stress on Phase insulation: Higher peak voltages between phases ( V ph to ph) due to reflection of the voltage at the motor terminals. These can be up to twice the DC link voltage, depending on the cable length and rise time. Stress on slot insulation: Higher peak voltages between the winding and the stator laminated core ( V ph to earth). Stress on the turn insulation : Considerably higher electrical stress between the turns ( V turns) due to the rise time and steep voltage change at the entry coils ( which are connected to the motor terminals).

Voltages
V ph tp ph

V ph to ph upto 2x due to long cable

Limiting values
Effects of rise time and voltages on the stresses in the insulation
Evaluation of suitability of the motor insulation for VFD operation: Determine phase to phase voltage at motor terminals. Determine the rise time ( from VFD manufacturer) . Short rise time : ( 0.01 to 0.5s ): The sharp voltage edge causes over proportionate voltage drop in the first coil sections of the winding. The maximum voltage value is based on the winding design and the turn insulation. Longer rise time : (more than 0.5s ): The maximum voltage value is constant and does not depend on the rise time. The limit is based on the phase and slot insulation.

Permissible Voltages
Graph showing permissible voltage vrs rise time for BBL motors
Peak Phase to phase voltage = 2 x 1.35 x 1.1 x Vn
( 2 for voltage doubling due to long cables, 1.35 for DC conversion and 1.1 for voltage variation)

Precautions to be taken by Users

Determine the Rise time and voltage at motor terminals.
This should be obtained from the VFD manufacturer along with the estimated Peak phase to phase voltage which will appear at the motor terminals. (This also depends on the cable length.) Order motor with suitable insulation scheme to match VFD.

Inform the above details to BBL while ordering the motors. We will select Insulation scheme I,II or III from the graph based on rise time and peak voltage. In case motor is already available and voltages are higher than permissible.
Use special circuit components between the VFD and the motor. eg. Sine filters Smoothing reactors dv/dt .filter circuits

BBL Forced cooled motor

Separate motor drives the cooling fan. Fan cowl is modified to mount separate fan motor At all speeds of main motor, fan motor runs at fixed speed and gives constant cooling No de-ration for main motor is required. It is offered in standard frame size Encoder mounting arrangement is optional Power source of fan motor is separate so interlocking of main motor and fan motor contactors is necessary.

BBL Forced cooled motor

Types of bearing currents.

A. Classical mechanism of bearing currents. These are caused by asymmetries in the magnetic circuit of the motor due to, 1. Manufacturing tolerances. 2. The size of the machine. 3. Design parameters eg. N1, N2 4. Number of poles. 5. Material anistropies. These assymetries cause alternating flux around the shaft which induces a voltage in the shaft. This can be measured between shaft ends. Problem only in larger machines. ( Voltage >= 500mV)

Paths of bearing currents

Types of bearing currents

B. Currents due to VFD's 1. The Circular current. 2. The rotor shaft current. 3. The EDM current.( Electrostatic Discharge Machining) Bearing currents in VFD's are a problem of the whole drive configuration and not only the motor. High frequency components ( 10 kHz up to several 100kHz) are important.

The following are currently available bearing current reduction methods:

Improve the high-frequency grounding connections at each equipment, right from the transformer to the motor including the drive and the driven equipment. Use high frequency earthing conductors made of finely stranded braided copper wires with a large cross section.

Install one insulated bearing on the non drive end of the motor. Install Sine filters / dv/dt filters /smoothing reactors between drive and motor. Install two insulated bearings on the motor. Install a shaft grounding brush across one motor bearing.

Latest IEC draft standard : IEC 60034-25 : A.C. Motors when used in power drive systems Application guide Important clauses: 4.3 : Torque speed 4.3.3 : Limiting factors for torque speed 4.3.5 : Cooling 4.4 : Motor requirements 5.1 : Increase in losses, Fig 3 7.3 : Winding electrical stresses, Fig 13 7.5 : Methods to reduce voltage stresses. 8: Bearing currents 8.6 : Preventing bearing damage, Table 5 9.1.2 : Earthing

Optional Accessories for VFD motors

Temperature sensing devices like thermistors, thermostats etc. Encoder mounting arrangement Forced cooling. Insulated bearing on NDE side of the motor. Special insulation if system voltage is higher than 500V.

Maintenance ( Ref IS 900) When an electric motor has been properly installed, It requires little attention later on to keep it working properly. If the motor is kept clean and dry, and properly lubricated periodically, it will give trouble free service for a long time. The operation of cleaning, lubrication and inspection at regular intervals should be carried out according to a schedule, and proper records should be kept of what has been done on each occasion. Motors should be cleaned by blowing air at regular intervals to keep their ventilating passages clear, particularly when operating in dusty atmospheres.

Precautions to be taken during maintenance ( Ref IS 900) Terminals and screw connections shall be kept clean and tight. If they become dirty or corroded, they should be disconnected and all contact surfaces made clean and smooth. Bad contact leads to sparking and ultimate breakdown. Only the required quantity of grease should be put into the bearings as too much grease will also cause overheating in the same ways as too little grease.

Precautions to be taken by Rewinders

Determine the location of the failure. If it is in the entry coil , then high dV/dt could be the problem Never burn the winding for easy removal. Use dual coat winding wire. Increase slot and phase to phase insulation if possible. Use VPI impregnation with solventless resin. Recommend insulated bearing on NDE if bearing has failed due to bearing currents. If complete overheating is observed go for forced cooling

arrangement.

Summary and Conclusions

There exists a national standard IS 12615: 2004 (Revision 1) for energy efficient three phase induction motors from 0.37kW to 160 kW. (Revision 2) will bring it in line with IEC stds and extends range to 375 kW Payback period of eff1 motor over eff2 motor is approx 2500 working hrs. EE motors when used with VFDs give much more savings. Proper selection of EE motors to be used with VFD is a must w.r.t. insulation and bearings Installation methods affect the life of the motor when used with VFDs. Maintenance of running motors is very important Extra care should be taken when rewinding a EE motor Use of Energy efficient motors is on the rise.

Thank You