Guide to Drives

Allen-Bradley 353
Measuring Torque
If the amount of torque required to drive a machine cannot be
determined from the machine builder, it can be easily measured.
Fasten a pulley securely to the shaft which the motor is to drive.
Secure one end of a cord to the outer surface of the pulley and wrap a
few turns of the cord around the pulley. Tie the other end of the cord
to a spring scale (see Figure 28).
Figure 28
Measuring Machine Torque Required
Pull on the scale until the shaft turns. The force in pounds indicated
on the scale, multiplied by the radius of the pulley (from the
centerline to the outside edge) in feet gives the torque value in lb-ft.
On some machines, this torque may vary as the shaft rotates. The
highest value of torque must be used in selecting a drive.
The running torque required by a machine will be approximately
equal to the starting torque, if the load is composed almost entirely of
friction. When the load is primarily inertia or windage, the
characteristics of the inertia or windage producing elements must be
determined.
The running torque of a machine can be accurately determined. An
armature controlled DC drive of known horsepower rating can be
used in making a test run (along with a shunt wound or permanent
magnet DC motor). The DC drive should have an ammeter in the
armature circuit so significant current readings can be observed and
recorded throughout the speed range of the machine. Since armature
current and torque are directly proportional, the current readings will
provide accurate information for selecting the drive rating required by
the machine.
Most machines require a higher torque value at breakaway. Once the
machine is running, the torque requirement will decrease. Many
drives have 150% load capability for 1 minute, which may allow the
required additional breakaway torque to be obtained without
increasing the drive horsepower rating.
Guide to Drives
354 Allen-Bradley
General Rules
If the running torque is equal to or less than the breakaway torque
divided by 1.5, use the breakaway torque divided by 1.5 as the full-
load rated torque required to determine the motor horsepower.
If the running torque is greater than breakaway torque divided by 1.5,
but less than the breakaway torque, use the running torque as the full-
load rated torque required to determine the motor horsepower.
Calculating Torque
(Acceleration Torque Required for Rotating Motion)
Some machines must be accelerated to a given speed in a certain
period of time. The torque rating of the drive may have to be
increased to accomplish this objective. The following equation may
be used to calculated the average torque required to accelerate a
known inertia (WK
2
). This torque must be added to all the other
torque requirements of the machine when determining the drive and
motors required peak torque output.
Equation 5
Where:
T = Acceleration torque (lb-ft.)
WK
2
= total system inertia (lb-ft.
2
) that the motor must accelerate.
This value includes motor armature, reducer and load.
N = Change in speed required (RPM)
t = time to accelerate total system load (seconds)
Note: The number substituted for (WK
2
) in Equation 5 must be in units
of lb-ft.
2
.
The same formula can also be used to determine the minimum
acceleration time of a given drive, or if a drive can accomplish the
desired change in speed within the required time period.
Equation 6
Rearranged Equation:
Most drives have 150% load capability for 1 minute. Therefore
additional acceleration torque will be available without increasing the
drive horsepower rating.
T
WK
2
N ( )
308t
----------------------------- =
t
WK
2
N ( )
308T
-------------------------------- =
Guide to Drives
Allen-Bradley 355
General Rules
If the running torque is equal to or less than the accelerating torque
divided by 1.5, use the accelerating torque divided by 1.5 as the full-
load torque required to determine the motor horsepower.
If the running torque is greater than accelerating torque, use the
running torque as the full-load rated torque required to determine the
motor horsepower.
Calculating Horsepower
Note: The following equations for calculating horsepower are meant
to be used for estimating purposes only. These equations do not include
any allowance for machine friction, windage or other factors. These
factors must be considered when selecting a drive for a machine
application.
Once the machine torque is determined, the required horsepower is
calculated using the formula:
Equation 7
Where:
HP = Horsepower
T = Torque (lb-ft.)
N = Speed of motor at rated load (RPM)
If the calculated horsepower falls between standard available motor
ratings, select the higher available horsepower rating. It is good
practice to allow some margin when selecting the motor horsepower.
For many applications, it is possible to calculate the horsepower
required without actually measuring the torque required. The
following equations will be helpful:
Conveyors
Equation 8
Equation 9
HP
T N
5252
------------ =
HP (Vertical)
Force/Weight (lbs.) Velocity (FPM)
33 000 ,
-------------------------------------------------------------------------------- =
HP (Horizontal)
Force/Weight (lbs.) Velocity (FPM) Coef. of Friction
33 000 ,
------------------------------------------------------------------------------------------------------------------------- =
Guide to Drives
356 Allen-Bradley
Web Transport Systems and Surface Winders
Equation 10
The tension value used in this calculation is the actual web
tension for Surface Winder applications.
The above tension value is the tension differential (Downstream
Tension Upstream Tension) for sectional drives.
Constant Tension Center Winders
(Armature Control Only)
Equation 11
Note: The required HP (armature control tension) can be reduced by
taper ratio.
Constant Tension Center Winders
(Field Control Only)
Equation 12
Fans and Blowers
Equation 13
Equation 14
Equation 15
HP
Tension (lbs.) Line Speed (FPM)
33 000 ,
---------------------------------------------------------------------------- =
HP
Max. Tension (lbs.) Max. Line Speed (FPM)
33 000 ,
---------------------------------------------------------------------------------------------------- Buildup =
HP
Tension (lbs.) Line Speed (FPM)
33 000 ,
---------------------------------------------------------------------------- =
HP
CFM Pressure lbs/ft.
2
( )
33 000 , (Efficiency of Fan)
-------------------------------------------------------------- =
HP
CFM Pressure lbs/in.
2
( )
229 (Efficiency of Fan)
--------------------------------------------------------- =
HP
CFM (Inches of Water Gauge)
6356 (Efficiency of Fan)
---------------------------------------------------------------------- =
Guide to Drives
Allen-Bradley 357
Pumps
Equation 16
PSI = pounds per square inch
CFM = cubic feet per minute
GPM = gallons per minute
Specific gravity of water = 1.0
1 Cubic foot per second = 448 GPM
1 PSI = A head of 2,309 ft. for water weighing 62.36 lbs per cu. ft. at
62F
Efficiency of fan or pump = %/100
Displacement pump efficiency:
Displacement pumps may vary between 50 and 80% efficiency
depending on size of pumps.
Centrifugal pump efficiency:
500 to 100 gal. per min = 70 to 75%
1000 to 1500 gal. per min = 75 to 80%
Larger than 1500 gal. per min. = 80 to 85%
Inertia
Inertia is a measure of a bodys resistance to changes in velocity,
whether the body is a rest or moving at a constant velocity. The
velocity can be either linear or rotational.
The movement of Inertia (WK
2
) is the product of the weight (W) of
an object and the square of the radius of gyration (K
2
). The radius of
gyration is a measure of how the mass of the object is distributed
about the axis of rotation. Because of this distribution of mass, a
small diameter cylindrical part has a much lower inertia than a large
diameter part.
WK
2
or WR
2
WR
2
refers to the inertia of a rotating member that was calculated by
assuming the weight of the object was concentrated around its rim at
a distance R (radius) from the center (e.g. flywheel).
WK
2
refers to the inertia of a rotating member that was calculated by
assuming the weight of the object was concentrated at some smaller
radius, K (termed the radius of gyration). To determine the WK
2
of a
part, the weight is normally required (e.g. cylinder, pulley, gear).
HP
3960 (Efficiency of Pump)
GPM Head (ft.) (Specific Gravity)
--------------------------------------------------------------------------------- =
Guide to Drives
358 Allen-Bradley
Calculations
When performing inertia calculations, the two terms commonly used
are lb-ft.
2
and in-lb-sec.
2
. Many standard inertia calculations are
defined in lb-ft.
2
. However, in some motion control applications, such
as a servo system, inertias are defined in in-lb-sec.
2
. When
performing inertia calculations, be consistent with the formulas and
units used. An answer in lb-ft.
2
cannot be substituted for an answer in
units of in-lb-sec.
2
. The following examples will show calculations
using both sets of terms.
Cylinders
Inertia calculations of a cylinder.
Solid Cylinders
Equation 17
WK
2
0.000681 L (D)
4
=
Guide to Drives
Allen-Bradley 359
Hollow Cylinders
Equation 18
WK
2
= inertia of a cylinder (lb-ft.
2
)
= density of cylinder material in lb/in.
3
(see density chart below)
D
1
= inside diameter of cylinder (inches)
D
2
= outside diameter of cylinder (inches)
L = length of cylinder (inches)
Common Material Densities ()
Aluminum = 0.0977
Brass = 0.311
Cast Iron = 0.2816
Steel = 0.2816
In motion control applications, the moment of inertia calculations (J)
for cylinders can be performed using the following equations. Note
that the answer will be in units of in-lb-sec.
2
.
Solid Cylinders:
Inertia calculations of a cylinder (Motion Control Applications)
Equation 19
WK
2
0.000681 L D
2
( )
4
D
1
( )
4
[ ] =
J
0.5
D ( )
4
16
-------------


L
386.4
---------------------------------------------------------- =
Guide to Drives
360 Allen-Bradley
Hollow Cylinders:
Equation 20
J = inertia of a cylinder (in-lb-sec.
2
)
= 3.141
= density of cylinder material in lb/in.
3
(see density chart below)
D
1
= inside diameter of cylinder (inches)
D
2
= outside diameter of cylinder (inches)
L = length of cylinder (inches)
Common Material Weight Densities ()
Aluminum = 0.0977
Brass = 0.311
Cast Iron = 0.2816
Steel = 0.2816
Pulley/Gear
To calculate the inertia of a pulley or gear, divide up the piece as
shown in Figure 29. Using the same equation for calculating hollow
cylinders (Equation 21), perform the calculations of each separate
part and add them together for a total inertia. Note: WK
1
2
and WK
2
2

are the separate inertia calculations.
J
0.5
D
2
( )
4
D
1
( )
4

16
----------------------------------



L
386.4
--------------------------------------------------------------------------------- =
Guide to Drives
Allen-Bradley 361
Figure 29
Inertia of a Pulley or Gear
Equation 21
Note: To convert lb-ft.
2
to in-lb-sec.
2
: divide above answer by 2.68.
Figure 30 shows the same examples as Figure 29, but shows
calculations related to motion control applications. Because the
resulting answer needs to be in in-lb-sec
2
, the hollow cylinder
equation (Equation 22) is used.

Guide to Drives
362 Allen-Bradley
Figure 30
Inertia of a Pulley of Gear (Motion Control Applications)
Equation 22
Total Inertia = J1 + J2 = 0.009 + 0.0051 = 0.0141 in-lb-sec
2
Note: To convert in-lb-sec.
2
to lb-ft
2:
multiply above answer by 2.68

Guide to Drives
Allen-Bradley 363
Calculations Using Weight Or Dimensions
Inertia equations require weight and size of the particular object. The
weight of an object will generally give the best value of inertia.
However, in some motion control applications, the weight is not
known. Therefore in those applications, the equation will depend on
size, which provides a good estimate of inertia.
To calculate the inertia of a shaft (J), use the equations in Figure 31
when either the weight or dimensions of the shaft are known. Note:
The resulting answer will be in units of in-lb-sec.
2
.
Figure 31
Inertia Calculations using Dimensions or Weight
Equation 23
Equation 24
Equation 25
Equation 26
J
.5
D ( )
4
16
-------------


L
386.4
------------------------------------------------------- =
J
.5 3.141 0.2816
1 ( )
4
16
------------


1
386.4
--------------------------------------------------------------------------- .000072 in-lb-sec
2
= =
Volume of the rod 3.141 (R)
2
Length =
3.141 (.5)
2
1 =
.785 in
3
=
Weight of the rod VOLUME DENSITY =
.785 in
3
.2816 =
.221 lbs =
lbs
in
3
--------
J
W
386.4
---------------
R
2
--------------------


2
=
J
.221
386.4
---------------
.5
2
--------------------


2
.000072 in-lb-sec
2
= =
Guide to Drives
364 Allen-Bradley
Speed Reducer Selection
Note: Adjustable speed drive motors can be damaged by continuous
operation at low speed and rated torque. The motors cooling ability
diminishes as speed is reduced. Servomotors, however, can supply full
rated torque down to zero speed.
The motor should always be coupled to the driven machine by a
power transmission that will permit maximum motor RPM at
maximum machine speed. The power transmission may be a simple
belt-sheave or sprocket-chain arrangement or a compact gear reducer.
In applications requiring speed reductions greater than 5:1, the gear
reducer may be the most economical choice.
Gear Reducer Selection
A gear reducer transmits power by an arrangement of various forms
of gears. It provides an efficient, positive drive to change speed,
direction and torque. This may mean a change of speed with a
corresponding change in torque or a change in output direction or
position. A common result is a combination of the above.
The gear reducer serves as a torque amplifier, increasing the torque
by a factor proportional to the reducer ratio, less an efficiency factor.
See Figure 32.
Figure 32
Gear Reducer Characteristics
A 1 HP, 1750 RPM motor has an output torque of 3 lb-ft. If a 30:1
ratio reducer with 85% efficiency is used, the reducer output torque
will be 3 x 30 x 0.85 = 76.5 lb-ft.
A typical application involves selecting a gear reducer that permits
the drive motor to operate at base speed when the driven machine is at
maximum speed. The gear reducer should also provide adequate
torque to drive the machine.
Guide to Drives
Allen-Bradley 365
Application Example
A 1750 RPM motor is selected for a machine which is to operate at a
57.5 RPM maximum speed and requires 70 lb-ft. of torque.
To find the answer, the following two steps must be accomplished.
1. Determine the required ratio:
Equation 27
Note: When the calculated reducer ratio is not a standard speed
reducer ratio, a chain, belt or additional gears with further reduction
are necessary (located on the input or output side).
2. Determine the motor torque and horsepower:
A 30:1 gear reducer is selected which is capable of supplying 70 lb-ft.
of output torque. Since the machine torque requirement is known, this
value is divided by the reduction ratio and efficiency factor to arrive at
required motor torque (T
M
).
Equation 28
Since a 1 HP, 1750 RPM base motor delivers 3 lb-ft. of torque, it is
chosen for this application along with a 30:1 gear reducer with a
minimum of 70 lb-ft. output torque.
Where the reduction ratio permits the use of a chain or belt, the same
formulas are used as for reducers.
Gear Reducer, Overhung Load
An overhung load (OHL) is defined as dead weight the gear reducer
bearings can support on an output shaft at a distance equal to the shaft
diameter. This distance is measured from the outside end of the
bearing housing along the shaft (see the following figure). If the
acting load is at a point different from the OHL point, it must be
converted to the reference point and compared to the manufacturers
catalogued value.
Reducer Ratio
Maximum Motor RPM
Maximum Driven Machine RPM
------------------------------------------------------------------------------------ =
Reducer Ratio
1750
57.5
------------- 30.4 or a 30:1 ratio = =
T
M
Required Torque (lb-ft.)
Reducer Ratio Efficiency Factor
-------------------------------------------------------------------------- =
T
M
70
30 0.85
--------------------- 2.75 lb-ft. = =
Guide to Drives
366 Allen-Bradley
When a gear reducer is driven by a belt, chain or gear drive, or when
the gear reducer drives a driven unit through a belt chain or gear
drive, an overhung load (radial thrust) is produced. The overhung load
must not exceed the rating of the gear reducer as listed by the
manufacturer. The magnitude of the overhung load should always be
kept to a minimum. Excessive loads could lead to fatigue failure of
either bearing or shaft. The sprocket or pulley should always be
located as close to the gear housing as possible.
Increasing the sprocket or pulley diameter results in a reduced
overhung load. Use the following equation to determine the overhung
load:
Equation 29
Note: K is constant which is:
1.0 for chain drives
1.25 for gears or gear-belt drives
1.50 for V-belt drive
2.50 for flat-belt drives
No overhung loads are encountered when the gear reducer is directly
coupled to the motor and/or driven machine shaft. However, care
must be taken in aligning the shafts to avoid pre-loading bearings by
misalignment.
OHL (lb)
2 Shaft Torque (lb-in.) K
Diameter sprocket, sheave, pulley, gear (in.)
------------------------------------------------------------------------------------------------ =
Guide to Drives
Allen-Bradley 367
Tables and Formulas Introduction
The data contained in this section is provided for reference only.
Many formulas are for estimating only because they cannot consider
all factors in every machine application. Many formulas can assist the
reader by demonstrating basic physical or electrical relationships
needed to understand a more abstract concept in control or motor
operation.
Other data such as conversion factors is included for your
convenience to provide a more comprehensive resource when
working in an international design environment.
Note: The following equations for calculating horsepower are meant
to be used for estimating purposes only. These equations do not include
any allowance for machine friction, windage or other factors. These
factors must be considered when selecting a drive for a machine
application.
Horsepower Formulas
Rotating Objects
Where:
T = Torque (lb-in)
N = Speed (RPM)
Where:
T = Torque (lb-ft)
N = Speed (RPM)
Objects in Linear Motion
Where:
F = Force (lb.)
V = Velocity (ft./min.)
Where:
F = Force (lb.)
V = Velocity (in./min.)
HP
T N
63 000 ,
---------------- =
HP
T N
5252
------------ =
HP
F V
33 000 ,
---------------- =
HP
F V
396 000 ,
------------------- =
Guide to Drives
368 Allen-Bradley
For Pumps
Where:
GPM = Gallons per Minute
Head = Height of Water (ft.)
Efficiency of Pump = %/100
PSI = Pounds per Square Inch
Specific Gravity of Water = 1.0
1 Cu. Ft. Per Sec. = 448 GPM
1 PSI = A head of 2.309 ft. - for water weighing 62.36 lbs. per cu. ft.
at 62F
For Fans and Blowers
Where:
CFM = Cubic Feet per Minute
PSF = Pounds per Square Foot
PIW = Inches of Water Gauge
PSI = Pounds per Square Inch
Efficiency of Fan = %/100
For Conveyors
Where:
F = Force (lbs.)
V = Velocity (ft./min.) Ball or Roller Slide = .02
Coef. of Friction:
Dovetail Slide = .20
Hydrostatic Ways = .01
Rectangle Ways with Gib = .1 - .25
HP
GPM Head Specific Gravity
3960 Efficiency of Pump
--------------------------------------------------------------------- =
HP
GPM PSI Specific Gravity
1713 Efficiency of Pump
----------------------------------------------------------------- =
HP
CFM PSF
33 000 , Efficiency of Fan
----------------------------------------------------------- =
HP
CFM PIW
6356 Efficiency of Fan
----------------------------------------------------- =
HP
CFM PSI
229 Efficiency of Fan
-------------------------------------------------- =
HP (Vertical)
F V
33 000 ,
---------------- =
HP (Horizontal)
F V Coef. of Friction
33 000 ,
----------------------------------------------------- =
Guide to Drives
Allen-Bradley 369
Torque Formulas
Where:
T = Torque (lb-ft.)
HP = Horsepower
Speed (RPM)
Where:
T = Torque (lb-ft.)
F = Force (lbs.)
R = Radius (ft.)
Where:
T = Torque (lb-ft.)
WK
2
= Inertia reflected to the Motor Shaft (lb-ft.
2
)
RPM = Change in Speed
t = Time to Accelerate (sec.)
Note: To change lb-ft.
2
to in-lb-sec.
2
: Divide by 2.68
To change in-lb-sec.
2
to lb-ft
2
: Multiply by 2.68
AC Motor Formulas
Where:
Sync Speed = Synchronous Speed (RPM)
Freq. = Frequency (Hz)
Where:
FL Speed = Full Load Speed (RPM)
Sync Speed = Synchronous Speed (RPM)
Where:
WK
2
= Inertia (lb-ft.
2
)
T
HP 5252
N
------------------------ =
T F R =
T (accelerating)
WK
2
RPM
308 t
-------------------------------- =
Sync Speed
Freq. 120
Number of Poles
---------------------------------------- =
% Slip
Sync Speed FL Speed ( ) 100
Sync Speed
------------------------------------------------------------------------- =
Reflected WK
2
WK
2
of Load
(Reduction Ratio)
2
-------------------------------------------------- =
Guide to Drives
370 Allen-Bradley
Electrical Formulas
Ohms Law
Where:
I = Current (Amperes)
E = EMF or Voltage (Volts)
R = Resistance (Ohms)
Power In DC Circuits
Where:
P = Power (Watts)
I = Current (Amperes)
E = EMF or Voltage (Volts)
kW = Kilowatts
kWH = Kilowatt-Hours
Power In AC Circuits
Where:
kVA = Kilovolt-Amperes
I = Current (Amperes)
E = EMF or Voltage (Volts)
Where:
KW = Kilowatts
I = Current (Amperes)
E = EMF or Voltage (Volts)
PF = Power Factor
W = Watts
V = Volts
kVA = Kilovolt-Amperes
I
E
R
---- = R
E
I
---- = E I R =
P I E =
kW
I E
1000
---------- =
HP
I E
746
---------- =
kWH
I E Hours
1000
------------------------------ =
kVA (1)
I E
1000
---------- = kVA (3)
I E 1.73
1000
-------------------------- =
kW (1)
I E PF
1000
----------------------- =
kW (2)
I E PF 1.42
1000
--------------------------------------- =
kW (3)
I E PF 1.73
1000
--------------------------------------- =
PF
W
V I
----------
kW
kVA
----------- = =
Guide to Drives
Allen-Bradley 371
Calculating Motor Amperes
Where:
HP = Horsepower
E = EMF or Voltage (Volts)
Eff = Efficiency of Motor (%/100)
kVA = Kilovolt Amperes
kW = Kilowatts
PF = Power Factor
Other Formulas
Calculating Accelerating Force For Linear Motion
Where:
F = Force (lbs.)
W = Weight (lb.)
V = Change in Velocity (FPM)
t = Time to accelerate weight (seconds)
Calculating Minimum Accelerating Time of a Drive
Where:
t = Time required to accelerate load (seconds)
WK
2
= Total inertia that the motor must accelerate (lb-ft.
2
).
This includes motor rotor gear reducer and load.
N = Change in speed required (RPM)
T = Accelerating torque (lb-ft.)
Note: To change lb-ft.
2
to in-lb-sec.
2
: Divide by 2.68
To change in-lb-sec.
2
to lb-ft.
2
: Multiply by 2.68
Where:
RPM = Revolutions per Minute
FPM = Feet per Minute
D = Diameter (ft.)
Motor Amperes
HP 746
E 1.732 Eff PF
---------------------------------------------- =
Motor Amperes
kVA 1000
1.73 E
-------------------------- =
Motor Amperes
kW 1000
1.73 E PF
------------------------------- =
F (Acceleration)
W V
1933 t
------------------ =
t
WK
2
N
308 T
------------------------ =
RPM
FPM
.262 D
------------------- =
Guide to Drives
372 Allen-Bradley
Where:
WK
2
= Inertia (lb-ft.
2
)
RPM = Revolutions per Minute
Engineering Constants
Temperature
Length
Weight
WK
2
Reflected to Motor Load WK
2
Load RPM
Motor RPM
------------------------------


2
=
0C = Freezing point of water
32F = Freezing point of water = 0C
100C = Boiling point of water at atmospheric pressure
212F = Boiling point of water at atmospheric pressure
1.85DF = 15DC
0.252 Calories = 1 Btu
-270C = Absolute Zero
-459.6F = Absolute Zero
1760 Yards = 1 Mile
25.4 mm = 2.54 cm = 1 in.
3 ft. = 1 Yard
3.2808 ft = 1 m
39.37 in. = 1 m = 100 cm = 1000 mm
5280 ft. = 1 Mile
0.62137 Miles = 1 km
16 oz. = 1 lb.
2.2046 lb. = 1 kg.
2.309 ft. water at 62F = 1 PSI
28.35 gm = 1 oz.
59.76 lbs. = Weight of 1 cu. ft. of water at 212F
0.062428 lb. per cu = 1 kg/cu. m
62.355 lbs. = Weight of 1 cu. ft. water at 62F
8-1/3 (8.32675) lbs. = Weight 1 gallon water at 62F
Guide to Drives
Allen-Bradley 373
Power
Area
Mathematic
Pressure
1.3410 HP = 1 kW
2,545 Btu per hour = 1 HP
33,000 ft-lb. per minute = 1 HP
550 ft-lb. per second = 1 HP
745.7 W = 1 HP
10.764 sq. ft. = 1 sq. m
1,273,239 circular mils = 1 sq. in.
144 sq. in = 1 sq. ft.
645 mm
2

= 1 sq. in.
9 sq. ft. = 1 sq. yard
0.0929 sq. m = 1 sq. ft.
1.4142 = square root of 2
1.7321 = square root of 3
3.1416 = = ratio of circumference of circle to
diameter = ratio of area of a circle to square
of radius
57.296 = 1 rad. (angle)
0.7854 x diameter squared = area of a circle
14.223 PSI = 1 kg per sq. cm = 1 metric atmosphere
2.0355 in. Hg at 32F = 1 PSI
2.0415 in. Hg at 62F = 1 PSI
2,116.3 PSF = atmospheric pressure
27.71 in. water at 62F = 1 PSI
29.921 in. Hg at 32F = atmospheric pressure
30 in. Hg at 62F = atmospheric pressure (approximate)
33.974 ft. water at 62F = atmospheric pressure
0.433 PSI = 1 ft. of water at 62F
5196 PSF = 1 in. water at 62F
760 mm Hg = atmospheric pressure at 0C
0.07608 lb. = weight 1 cu. ft. air at 625F and 14.7 PSI
Guide to Drives
374 Allen-Bradley
Volume
Standard Abbreviation Descriptions
Temperature
Length
Weight
1,728 cu. in. = 1 cu. ft.
231 cu. in = 1 gallon (U.S.)
277.274 cu. in = 1 gallon (British)
27 cu. ft. = 1 cu. yard
31 gallon
(31.5 U.S. Gallons)
= 1 Barrel
35.314 cu. ft. = 1 cu. m
3.785 liters = 1 gallon
61.023 cu. in. = 1 liter
7.4805 gallon = 1 cu. ft.
deg = degrees
C = Celsius (Centigrade)
F = Fahrenheit
Btu = British Thermal Unit
yd. = yard
m = meter
mm = millimeter (1/1000 of a meter)
cm = centimeter 1/100 of a meter)
in. = inch
ft. = feet
km = kilometer
oz. = ounce
lb. = pound
kg. = kilogram
g = gram
Guide to Drives
Allen-Bradley 375
Electrical
Power/Energy
Work/Inertia
Area
Rotation Rate
= Ohms
= Phase
V = Volts
A = Amperes
a = milliamperes
ma = microamperes
mV = millivolts
KV = kilovolts
kVA = kilovolt-Ampere
HP = Horsepower
W = Watt
kW = Kilowatt
kWH = Kilowatt-Hours
ft-lb. = foot pounds
WK
2

= moment of inertia
N-m
2
= Newton meters
2
sq. ft. = square feet
sq. m = square meters
mil = unit of length or angular measurement
mm
2

= square millimeters
sq. in. = square inch
FPM = feet per minute
FPS = feet per second
m/s = meters per second
mph = miles per hour
cfm = cubic feet per minute
Guide to Drives
376 Allen-Bradley
Mathematic
Pressure
Volume
Conversion Factors
Length
Example: 10 Meters x 3.3281 = 32.81 Feet
= pi
rad. = radians
= Density
= Summation
= Change
kg. per sq. cm = kilograms per square centimeter
Hg = Mercury symbol
PSI = pounds per square inch
PSF = pounds per square foot
cu. = cubic
cu. in. = cubic inch
gal. = gallon
cu. ft. = cubic feet
ml = milliliter
fl. oz. = fluid ounce (U.S.)
To Convert: To: Multiply By:
Meters Feet 3.281
Meters Inches 39.37
Inches Meters 0.0254
Feet Meters 0.3048
Millimeters Inches 0.0394
Inches Millimeters 25.4
Thread/Inch Millimeter Pitch Divide Into 25.4
Yards Meters 0.914
Guide to Drives
Allen-Bradley 377
Area
(0.5 x 10
-7
Circular Mils = .00000005 m
2
)
Example: 100 Circular Mils y 0.5 x 10
-9
= 0.5 x 10
-7
m
2
Power
Example: 1500W x .00134 = 2.01 HP
Rotation/Rate
Example: 1800 RPM x 6.00 = 10800 deg./sec.
To Convert: To: Multiply By:
Circular mil
Meter
2
0.50 y 10
-9
Yard
2
Meter
2
0.8361
To Convert: To: Multiply By:
Watts HP 0.00134
ft-lb./min. HP 0.0000303
HP kW 0.746
To Convert: To: Multiply By:
RPM deg./sec. 6.00
RPM Rad./sec. 0.1047
deg./sec. RPM 0.1667
Rad./sec. RPM 0.540
FPM m/s 0.00508
FPS m/s 0.3048
gal./min.
cm
3
/sec.
63.09
in./sec. m/sec. 0.0254
km/hr. m/sec. 0.2778
mph m/sec. 0.447
mph km/hr. 1.609
RPM rad./sec. 0.1047
yd.
3
/min. m
3
/sec.
0.01274
Guide to Drives
378 Allen-Bradley
Moment of Inertia
Example: 25 Newton-Meters
2
x 2.42 = 60.5 lb-ft.
2
Mass/Weight
Example: 50 oz. x 31.1 = 1555 deg./sec.
Torque
Example: 30 Newton-Meters x 0.7376 = 22.13 lb-ft.
Volume
Example: 250 cm
3
x .000001 = .00025 m
3
To Convert: To: Multiply By:
Newton-Meters
2
lb-ft.
2
2.42
oz-in.
2
lb-ft.
2
0.000434
lb-in
2
lb-ft.
2
0.00694
Slug-ft.
2
lb-ft.
2
32.17
oz-in-sec.
2
lb-ft.
2
0.1675
in-lb-sec.
2
lb-ft.
2
2.68
To Convert: To: Multiply By:
oz. g 31.1
kg lbs. 2.205
lb. kg 0.4536
Newtons lbs. 0.2248
To Convert: To: Multiply By:
Newton-Meters lb-ft. 0.7376
lb-ft. Newton-Meters 1.3558
lb-in. lb-ft. 0.0833
lb-ft. lb-in. 12.00
To Convert: To: Multiply By:
cm
3
(ml) m
3
0.00001
fl. oz.
cm
3
29.57
ft.
3
of water (39.2F)
kg (or liter) 28.32
cfm
m
3
/sec.
0.000472
liter
m
3
0.001
yd.
3
m
3
0.7646
Guide to Drives
Allen-Bradley 379
Temperature
Fractional Inch to Equivalent Millimeters and Decimals
To Convert: To: Multiply By:
deg. F deg. C deg. C = (deg. F - 32)
1.8
deg. C deg. F deg. F = (deg. C x 1.8) + 32
Example: 62F
68 32 ( )
1.8
-------------------------- 20C = =
20C 20 1.8 ( ) 32 + 68F = =
Inch
Equivalent
Inch
Equivalent
Inch
Equivalent
Inch
Equivalent
mm Decimal mm Decimal mm Decimal mm Decimal
1
/
64
.3969 .0156
17
/
64
6.7469 .2656
33
/
64
13.0969 .5156
49
/
64
19.4469 .7656
1
/
32
.7938 .0313
9
/
32
7.1438 .2813
17
/
32
13.4938 .5313
25
/
32
19.8438 .7813
3
/
64
1.1906 .0469
19
/
64
7.5406 .2969
35
/
64
13.8906 .5469
51
/
64
20.2406 .7969
1
/
16
1.5875 .0625
5
/
16
7.9375 .3125
9
/
16
14.2875 .5625
13
/
16
20.6375 .8125
5
/
64
1.9844 .0781
21
/
64
8.3344 .3181
37
/
64
14.6844 .5781
53
/
64
21.0344 .8281
3
/
32
2.3813 .0938
11
/
32
8.7313 .3438
19
/
32
15.0813 .5938
27
/
32
21.4313 .8438
7
/
64
2.7781 .1094
23
/
64
9.1281 .3594
39
/
64
15.4781 .6094
55
/
64
21.8281 .8594
1
/
8
3.1750 .1250
3
/
8
9.5250 .3750
5
/
8
15.8750 .6250
7
/
8
22.2250 .8750
9
/
64
3.5719 .1406
25
/
64
9.9219 .3906
41
/
64
16.2719 .6406
57
/
64
22.6219 .8906
5
/
32
3.9688 .1563
16
/
32
10.3188 .4063
21
/
32
16.6688 .6563
29
/
32
23.0188 .9063
11
/
64
4.3656 .1719
31
/
64
10.7156 .4219
43
/
64
17.0656 .6719
59
/
64
23.4156 .9219
3
/
16
4.7625 .1875
7
/
16
11.1125 .4375
11
/
16
17.4625 .6875
15
/
16
23.8125 .9375
13
/
64
5.1594 .2031
29
/
64
11.5094 .4531
46
/
64
17.8594 .7031
61
/
64
24.2094 .9531
7
/
32
5.5563 .2188
16
/
32
11.9063 .4688
23
/
32
18.2563 .7188
31
/
32
24.6063 .9688
15
/
64
5.9531 .2344
31
/
64
12.3031 .4844
47
/
64
18.6531 .7344
63
/
64
25.0031 .9844
1
/
4
6.3500 .2500
1
/
2
12.700 .5000
3
/
4
19.0500 .7500
Guide to Drives
380 Allen-Bradley
Inertia of a Solid Steel Shaft (lb-ft.
2
per inch of length)
Diameter
(Inches) Wk
2
Diameter
(Inches) Wk
2
Diameter
(Inches) Wk
2
Diameter
(Inches) Wk
2
Diameter
(Inches) Wk
2
Diameter
(Inches) Wk
2
3
/
4
0.00006 8 0.791
14
1
/
4
7.97 37 360.70 62 2844.3 87 11028
1 0.00007
8
1
/
4
0.895
14
1
/
2
8.54 38 401.30 63 3032.3 88 11544
1
1
/
4
0.0005
8
1
/
2
1.000
14
3
/
4
9.15 39 445.30 64 3229.5 89 12077
1
1
/
2
0.001
8
3
/
4
1.130 15 9.75 40 492.78 65 3436.1 90 12629
1
3
/
4
0.002 9 1.270 16 12.59 41 543.90 66 3652.5 91 13200
2 0.003
9
1
/
4
1.410 17 16.04 42 598.80 67 3879.0 92 13790
2
1
/
4
0.005
9
1
/
2
1.550 18 20.16 43 658.10 68 4115.7 93 14399
2
1
/
2
0.008
9
3
/
4
1.750 19 25.03 44 721.40 69 4363.2 94 15029
2
3
/
4
0.011 10 1.930 20 30.72 45 789.30 70 4621.7 95 15679
3 0.016
10
1
/
4
2.130 21 37.35 46 861.80 71 4891.5 96 16349
3
1
/
2
0.029
10
1
/
2
2.350 22 44.99 47 939.30 72 5172 97 17041
3
3
/
4
0.038
10
3
/
4
2.580 23 53.74 48 1021.80 73 5466 98 17755
4 0.049 11 2.830 24 63.71 49 1109.60 74 5774 99 18490
4
1
/
4
0.063
11
1
/
4
3.090 25 75.02 50 1203.07 75 6090 100 19249
4
1
/
2
0.079
11
1
/
2
3.380 26 87.76 51 1302.20 76 6422
5 0.120
11
3
/
4
3.680 27 102.06 51 1407.40 77 6767 110 28183
5
1
/
2
0.177 12 4.000 28 118.04 53 1518.80 78 7125 120 39914
6 0.250
12
1
/
4
4.350 29 135.83 54 1636.70 79 7498 130 54978
6
1
/
4
0.296
12
1
/
2
4.720 30 155.55 55 1761.40 80 7885 140 73948
6
1
/
2
0.345
12
3
/
4
5.110 31 177.77 56 1893.10 81 8286 150 97449
6
3
/
4
0.402 13 5.58 32 201.80 57 2031.90 82 8703 160 126152
7 0.464
13
1
/
4
5.96 33 228.20 58 2178.30 83 9135 170 160772
7
1
/
4
0.535
13
1
/
2
6.42 34 257.20 59 2332.50 84 9584 180 20271
7
1
/
2
0.611
13
3
/
4
6.91 35 386.80 60 2494.70 85 10048 190 250858
7
3
/
4
0.699 14 7.42 36 323.20 61 2665.20 86 10529 200 307988
Guide to Drives
Allen-Bradley 381
Maintenance of Industrial Control
Equipment
Periodic Inspection
Industrial control equipment should be inspected periodically.
Inspection intervals should be based on environmental and operating
conditions and adjusted as indicated by experience. An initial
inspection within 3 to 4 months after installation is suggested.
Applicable parts of the following guidelines should be used.
Contamination
If inspection reveals that dust, dirt, moisture or other contamination
has reached the control equipment, the cause must be eliminated.
This could indicate an incorrectly selected or ineffective enclosure,
unsealed enclosure openings (conduit or other) or incorrect operating
procedures. Replace any improperly selected enclosure with one that
is suitable for the environmental conditions - refer to National
Electrical Manufacturers Association (NEMA) Standards Publication
No. 250 for enclosure type descriptions and test criteria. Replace any
damaged or embrittled elastomer seals and repair or replace any other
damaged or malfunctioning parts (e.g., hinges, fasteners, etc.). Dirty,
wet, or contaminated control devices must be replaced unless they
can be cleaned effectively by vacuuming or wiping.
!
ATTENTION: Servicing energized industrial control
equipment can be hazardous. Severe injury or death can
result from electrical shock, burn, or unintended
actuation of controlled equipment. Recommended
practice is to disconnect and lockout control equipment
from power sources, and release stored energy, if
present. Refer to National Fire Protection Association
Standard No. NFPA70E, Part II for safety related
work practices including procedural requirements for
lockout-tagout, and appropriate work practices,
personnel qualifications and training requirements
where it is not feasible to de-energize and lockout or
tagout electric circuits and equipment before working
on or near exposed circuit parts.
Guide to Drives
382 Allen-Bradley
Operating Mechanisms
Check for proper functioning and freedom from sticking or binding.
Replace any broken, deformed or badly worn parts or assemblies
according to individual product renewal parts lists. Check for and
retighten securely and loose fasteners. Lubricate if specified in
individual product instructions.
Note: Allen-Bradley magnetic starters, contactors, and relays are
designed to operate without lubrication - do not lubricate these devices
since oil or grease on the pole faces (mating surfaces) of the operating
magnet may cause the device to stick in the ON mode. Some parts
of other devices are factory lubricated - if lubrication during use or
maintenance of these devices is needed, it will be specified in their
individual instructions. If in doubt, consult the nearest Allen-Bradley
sales office for information.
Contacts
Check contacts for excessive wear and dirt accumulations. Vacuum or
wipe contacts with a soft cloth if necessary to remove dirt. Contact
are not harmed by discoloration and slight pitting. Contacts should
never be filed, as dressing only shortens contact life. Contact spray
cleaners should not be used as their residues on magnet pole faces or
in operating mechanisms may cause sticking, and on contacts can
interfere with electrical continuity. Contacts should only be replaced
after silver has become badly worn. Always replace contacts in
complete sets to avoid misalignment and uneven contact pressure.
Terminals
Loose connections in power circuits can cause overheating that can
lead to equipment malfunction or failure. Loose connections in
control circuits can cause control malfunctions. Loose bonding or
grounding connections can increase hazards of electrical shock.
Check the tightness of all terminals and bus bar connections and
tighten securely any loose connections. Replace any parts or wiring
damage by overheating, and any broken wiring or bonding straps.
AC Hoods
Check for cracks, breaks or deep erosion. Arc hoods and arc chutes
should be repaired or replaced if damaged or deeply eroded.
Guide to Drives
Allen-Bradley 383
Coils
If a coil exhibits evidence of overheating (cracked, melted or burned
insulation), it must be replaced. In that event, check for and correct
overvoltage or undervoltage conditions, which can cause coil failure.
Be sure to clean any residues of melted coil insulation from other
parts of the device or replace such parts.
Pilot Lights
Replace any burned out lamps or damaged lenses.
Photoelectric Switches
The lenses of photoelectric switches require periodic cleaning with a
soft dry cloth. Reflective devices used in conjunction with
photoelectric switches also require periodic cleaning. Do not use
solvents or cleaning agents on the lenses or reflectors. Replace any
damaged lenses and reflectors.
Solid State Devices
Solid state devices require little more than a periodic visual
inspection. Printed circuit boards should be inspected to determine
whether they are properly seated in the edge board connectors. Board
locking tabs should also be in place. Necessary replacements should
be made only at the PC board or plug-in component level. Solvents
should not be used on printing circuit boards. Where blowers are
used, air filters should be cleaned or changed periodically depending
on the specific environmental conditions encountered.
!
ATTENTION: Use of other than factory
recommended test equipment for solid state controls
may result in damage to the control or test equipment
or unintended actuation of the controlled equipment.
Guide to Drives
384 Allen-Bradley
Locking and Interlocking Devices
Check these devices for proper working condition and capability of
performing their intended functions. If necessary, readjust, repair or
replace in accordance with individual product instructions.
Maintenance After a Fault Condition
Opening of the short circuit protective device (such as fuses or circuit
breakers) in a properly coordinated motor branch circuit is an
indication of a fault condition in excess of operating overload. Such
conditions can cause damage to control equipment. Before restoring
power, the fault condition must be corrected and any repairs or
replacements must be made to restore the control equipment to good
working order. Refer to NEMA standards Publication No. ICS-2, Part
ICS2-302 for procedures.
Final Check Out
After maintenance or repair of industrial controls, always test the
control system for proper functioning under controlled conditions that
avoid hazards in the event of a control malfunction.
For additional information, refer to NFPA70B, RECOMMENDED
PRACTICE FOR ELECTRICAL EQUIPMENT
MAINTENANCE, published by the National Fire Protection
Association.