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Motor Construction NEMA Motor Designations

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APPLICATION & SELECTION OF MOTORS & STARTERS

The selection of motors and starters for compressor applications involves such basic decisions as motor enclosure, starter enclosure, and voltage available. This selection process also involves sizing the motor for the correct horsepower at the worst operating condition and determining the type of starter to be applied from the standpoint of full voltage or reduced voltage. The first area that we will look at is the enclosure of the motor.

MOTOR ENCLOSURES
The most common enclosure types used in compressor applications are Open Drip Proof, Weather Protected 1, Weather Protected 2, Totally Enclosed Fan Cooled, and Explosion Proof. We will examine each of these and where they are most often applied. 1. Open Drip Proof Motors (ODP) Open Drip Proof motors are designed so that the cooling of the motor takes place by ambient air being pulled through the motor without the use of an external fan. These motors are usually applied in an indoor application where the presence of moisture and contaminants is at a minimum. This is the most common type of motor used for compressor applications. Weather Protected One (WPI) Weather Protected One motors are actually Open Drip Proof motors with modifications made for outdoor use in environments that have small amounts of moisture and contamination. The modifications made are the addition of screens on all of the openings to prevent anything larger than 3/4 of an inch in diameter from entering the motor and angling the openings on the stator frame to minimize the entrance of rain, snow, or contaminants to the motors internal parts. These motors are applied in outdoor applications where the ambient conditions are not severe. The addition of space heaters is recommended in this type of motor to keep condensation out of the motor when it is not operating. This type motor is quite common for compressor applications. Weather Protected Two (WPII) Weather Protected Two motors include a top hat assembly on the motor containing screens and filters that do not allow any outside air to enter the motor before it has been filtered and redirected, with 90 degree bends, a minimum of three times. This motor is applied in many outdoor applications where the conditions are severe and there are many contaminants in the air. The advantage for this type motor is that it can adequately cool the motor and keep out contaminants, much like the TEFC motor, at a reduced price. These motors are common for large outdoor compressor applications (above 500HP). They are not intended for use in atmospheres containing corrosive fumes or dust.

2.

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APPLICATION & SELECTION OF MOTORS & STARTERS

4.

Totally Enclosed Fan Cooled (TEFC) Totally Enclosed Fan Cooled motors are designed so that the stator and rotor of the motor is enclosed to prevent the entrance of moisture or contaminants to the internal parts of the motor. The motor has an externally mounted fan to push air over the motor to remove the heat generated during operation of the motor. These motors are used primarily in outdoor applications or applications where moisture and contaminants are a normal occurrence. TEFC motors are often used in division 2 hazardous locations. Explosion Proof Motors (XP) Explosion Proof motors are designed for use in hazardous locations as defined by Underwriters Laboratories (UL). These motors are totally enclosed to insure that an explosion or flame internal to the motor stays internal. These motors are cooled by external fans or air to water heat exchangers. The location that an explosion proof motor may be applied is based entirely on the tests completed by each individual manufacturer to obtain certification for use in hazardous locations as determined by Underwriter Laboratories. Explosion Proof motors require a UL label on their nameplate. These motors are used on compressors in petrochemical applications or in environments where there are vapors, gasses, or dust present that UL has determined explosive.

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TEMPERATURE RISE/INSULATION CLASS

The selection of the motor should also include looking at the rated temperature rise and the insulation class of the motor. The rated temperature rise of a motor is the permissible rise above ambient when operating under load. The insulation class is a rating determined by NEMA to handle the temperature rise of the motor. The following are the common NEMA standard insulation classes: INSULATION CLASS A B F H TEMPERATURE LIMIT 105 C (221 F) 130 C (275 F) 155 C (311 F) 180 C (356 F)

Motor insulation classes are based on the motor operating in a 40 degree C ambient. Operating temperature of the motor vs insulation class of the motor is the single largest factor in determining motor life. A general rule is that for every 10 degree C increase in operating temperature, over the insulation limit, motor life is cut in half. When specifying a motor you can insure operating tempertatures below insulation class rating by specifying a class F (155 C) insulation and a class B (130 C) temperature rise. All major motor manufacturers can meet this specification.
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APPLICATION & SELECTION OF MOTORS & STARTERS

HORSEPOWER/STARTING TORQUE
The final area that we will look at for motor selection is correct horsepower and starting torque. The required starting torque is necessary to determine the correct horsepower. This must come from the manufacturer of the driven equipment or in this case the compressor manufacturer. The starting torque will be given in lb ft values based on the following formula: lb ft = HORSEPOWER X 5250 RPM When the lb ft values are determined for a motor they are plotted vs the speed of the motor (see enclosed speed vs torque). The same type curve must be supplied by the manufacturer of the driven equipment. When both curves are available, the proper selection can be made. At this time, we must determine the means of staring the motor before we can continue with our selection. The reason for this is that if reduced voltage starting is required, you must remember that each type of reduced voltage starter has a different percentage of full-load torque available for accelerating the load. The most common starting methods for compressors are: Full Voltage (FV) Reduced-Voltage Autotransformer (RVAT) Part-Winding (PW) Wye-Delta (Y-D) Solid State Each of these types of starting has a different amount of starting torque available based on a percentage of full-load torque: STARTER TYPE FULL VOLTAGE RVAT 80% TAP RVAT 65% TAP PART-WINDING WYE-DELTA % FL LB FT 100% 64% 42% 50% 33%

The chart above is strictly based on torque available and does not take into consideration factors such as equipment being loaded or unloaded at start. The percentages are based on full load at rated voltage. The final step in determining which motor is required is comparing the torque available with any particular starter with the torque required to accelerate the load. When this has been done, the horsepower of the motor can be determined.

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APPLICATION & SELECTION OF MOTORS & STARTERS

EFFICIENCY/POWER FACTOR
Motor efficiency is defined as the ratio between work performed and the energy consumed to perform that work. To make an accurate decision on the efficiency of a motor, you must know the exact duty and load cycle. Most purchasing decisions of motors are made based on full-load efficiency. Motor manufacturers publish efficiencies at full load, 75% load, and 50% load to allow the user of the motor to make a better selection based on his particular duty cycle. Power Factor is defined as the ratio of true power to apparent power. Power factor is not usually given as much consideration on a motor specification as efficiency because power factor can easily be corrected by the use of power factor correction capacitors. Motor efficiencies and power factors could be the topic of an entire paper, however, for the basic selection process for motor and starter on a compressor application, I just want you to be aware of the availability of high efficiency and high power factor motors.

SUMMARY
When selecting a motor for any application, you must know the environment to select the enclosure, the driven equipment's load characteristics to determine horsepower and speed, plant distribution loads to determine voltage, and duty and load cycles to make an evaluation of efficiency and power factor. With this information a motor can be properly selected.

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APPLICATION & SELECTION OF MOTORS & STARTERS

ENCLOSURES
OPEN DRIP PROOF
This enclosure is primarily for use in clean, reasonably dry atmospheres. Incoming air enters through the air inlets in the bearing brackets. It is then uniformly circulated through the motor interior for effective cooling by the cooling fan and discharged from openings on the side of frame.

NEMA WEATHER-PROTECTED TYPE I (WPI)

This is similar to the open drip-proof motor with additional outdoor treatment and screens on the air inlets and air discharge openings.

ODP MOTOR

TOTALLY-ENCLOSED, FAN-COOLED TYPE (TEFC

TEFC motors are for installation in locations where dust or harmful gases exist. The external fan installed on the opposite drive end blows outside air along the cast iron frame fins. The outside air then effectively cools the interior air through cast iron frame. In this design, there is no free interchange of air between the inside and outside of the enclosure. It is also suitable for outdoor use and is easily cleaned.

TEFC MOTOR

TYPICAL CONSTRUCTION OF TOTALLY-ENCLOSED, FAN-COOLED MOTOR

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APPLICATION & SELECTION OF MOTORS & STARTERS

OPEN DRIP PROOF OR OPEN DRIP PROOF GUARDED TYPE

Incoming air enters through the air housing at the motors upper section, is uniformly circulated through the motor interior for effective cooling by a high-performance fan.

NEMA WEATHER PROTECTED TYPE II (WPII)

Foreign matter blown into the motor interior by wind, storms, or other weather influences are prevented from entering the interior by imparting a right-angle turn to the air flow three times inside the air housing on the motor top while maintaining an inlet air velocity of 600 ft/min. or less. Air filters on air inlet openings can be added environments where dust is a problem.

NEMA WEATHER PROTECTED TYPE 1 (WPI)

This is similar to the drip proof guarded motor with additional outdoor construction.

The TOSMIGHTY M80 series motors utilize a Top Hat structure which allows easy adaptation to any enclosure requirement.

TOTALLY ENCLOSED, WATER AIR COOLED TYPE (TEWAC) (CACW)

A water-to-air heat exchanger is installed in the top hat section of the motor. Water flowing through the water-to-air heat exchanger effectively cools the motor interior air.

TOTALLY ENCLOSED, FAN COOLED TYPE (TEFC) (CACA)

The outer fan installed on the opposite drive end blows outside air though tubes, located in the motor top hat. The outside air then effectively cools hot interior air at the air housing. The cooling tubes in the air housing can be easily cleaned by removing the outer fan cover.

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APPLICATION & SELECTION OF MOTORS & STARTERS

TYPICAL CONSTRUCTION
Frames 284T - 365T

TYPICAL CONSTRUCTION
Frames 404T - 445T

In addition to the IEEE standard 112A-method B, Toshiba Motors are given a rust-proof test, anti-dust test, and vibration test.
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APPLICATION & SELECTION OF MOTORS & STARTERS

TYPICAL CONSTRUCTION
Frames 284T - 445T
Improved Insulation System Dynamic Balanced Rotor

Efficient Ventilation

Air in Oversized Bearings

Air in Rugged Cast Iron End Brackets

Specially Designed Large Conduit Box

Distortion Free Frame

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APPLICATION & SELECTION OF MOTORS & STARTERS

INSULATION CLASSES
TEMPERATURE LIMIT 105 C 130 C 155 C 180 C (221 F) (275 F) (311 F) (356 F)

INSULATION CLASS A B F H

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APPLICATION & SELECTION OF MOTORS & STARTERS

TEMP vs INSULATION
1.15 ST - TEFC or ODP
CO 180 160 140 120 100 80 60 40 20 0
O 130 12345678901234567

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12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567 115 O 12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567 12345678901234567

155

40

40

B F INSULATION CLASS TEMPERATURE

12345678 12345678 12345678 12345678 RISE 12345678

AMBIENT
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APPLICATION & SELECTION OF MOTORS & STARTERS

STARTER TYPES
STARTER TYPE
FULL VOLTAGE RVAT 80% TAP RVAT 65% TAP PART WINDING WYE-DELTA

% FULL-LOAD TORQUE
100% 64% 42% 50% 33%

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APPLICATION & SELECTION OF MOTORS & STARTERS

VARIOUS METHODS FOR MOTOR STARTING

The electric motor starter is the important connecting link between the motor and the electric supply system. Properly applied, the motor starter can reduce the effects of motor starting on the system and on the driven load. The various methods available for starting squirrelcage motors are described in the following paragraphs.

GENERAL COMPARISONS
STARTER TYPE
Full Voltage Reduced Voltage Autotransformer 80% Tap 65% Tap 50% Tap Primary Resistor 80% Tap 65% Tap 50% Tap Primary Reactor *Same as Primary Resistor above* Reconnectable or Incremental Part Winding Low speed High speed Wye-Delta Solid State

MOTOR VOLTAGE
1.0

MOTOR TORQUE
1.0

MOTOR LINE CURRENT CURRENT

1.0 1.0

APPROX. COST
1.0

.8 .65 .5

.64 .42 .25

.8 .65 .5

* .64 * .42 * .25

5.0

.8 .65 .5

.64 .42 .25

.8 .65 .5

.8 .65 .5

4.0

1.0 1.0 1.0 .4-1.0

.5 .5 .33 .1-1.0

.5 .7 .33 .25-1.0

.5 .7 .33 .25-1.0

2.5

3.5 3.5-5.0

* The magnetizing current of the autotransformer is not included. Typically, this will be approximately 25% of the motor full load current.
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APPLICATION & SELECTION OF MOTORS & STARTERS

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APPLICATION & SELECTION OF MOTORS & STARTERS

SPEED vs TORQUE

PERCENT SPEED
TORQUE LB FT
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COMPRESSOR

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APPLICATION & SELECTION OF MOTORS & STARTERS

RWB II PLUS ROTARY SCREW COMPRESSOR UNITS

ENGINEERING DATA MOTOR SELECTION AND STARTING TORQUE
Motors must be sized adequately for all expected operating conditions since start-up, pull down, and load variations quite often require significantly more horsepower than nominal design. Motor starting torque capacity must also be considered, especially when other than across-theline start is employed. Motor starting and pull-up torque must be at least 20% greater than compressor requirements at maximum expected start-up conditions. Refer to the torque data. NOTE: Motor starting torque varies considerably with various manufacturers - obtain specific torque data for the motor being used. STARTING BREAK-AWAY (2) (3) TORQUE (1) INERTIA TORQUE MULTIPLIER WR2, LB-FT2 (FT-LB)

RWB MODEL

7 60 0.46 3 ___________________________________________ 7 76 0.58 3.5 ___________________________________________ 10 100 0.75 7 ___________________________________________ 10 134 1.00 8 ___________________________________________ 14 177 1.27 14 ___________________________________________ 14 222 1.60 17 ___________________________________________ 20 316 2.28 35 ___________________________________________ 20 399 2.87 43 (1) High Stage or Booster Application (2) Including standard compresssor coupling half (3) Inertia resolved to drive shaft

RWB SCREW COMPRESSOR SPEED vs STARTING TORQUE CURVE

- FULLY UNLOADED HIGH STAGE and BOOSTER HIGH STAGE BOOSTER

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SPEED vs TORQUE
FRICK 222/350 D2

TORQUE LB FT

APPLICATION & SELECTION OF MOTORS & STARTERS

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PERCENT SPEED

*
350 D2 YD

FRICK 222 185 PSIG

350 HP D2 S/S

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SPEED vs TORQUE
500HP MOTOR 460V / FRICK 222

TORQUE LB FT

APPLICATION & SELECTION OF MOTORS & STARTERS

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PERCENT SPEED

FRICK / 222 185 PSIG

500 D2 STD

500 D2 PREM

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APPLICATION & SELECTION OF MOTORS & STARTERS

EFFICIENCY
EFFICIENCY = OUTPUT INPUT = INPUT - LOSSES INPUT

LOSSES

POWER INPUT

POWER OUTPUT

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APPLICATION & SELECTION OF MOTORS & STARTERS

MOTOR LOSSES
LOSS
Stator Loss

DESIGN CHANGE
1) New Slot Geometry 2) Increased Amount of Wire in Slot 3) Decrease Length of Coil Extensions 1) 2) 3) 4) 5) 1) 2) 3) 4) New Slot Geometry Increase Flux Density in Air Gap Increase Rotor Bar Size Increase End Ring Size Increase Rotor Bar/End Conductivity Decrease Lamination Thickness Improve Coreplating Process Improve Annealing Process Improve Steel Grade (W / #)

Rotor Loss

Core Loss

Friction & Windage

1) Optimize Bearing Selection 2) Optimize Fan Design to Increase cfm; Decrease OD 1) 2) 3) 4) Insulate Rotor Bars Increase Air Gap Eliminate Rotor Skew Two Pass Machining

Stray Load Loss

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APPLICATION & SELECTION OF MOTORS & STARTERS

POWER FACTOR PENALTY .90 $ 10,000 X = $ 12,000 .75

SYSTEM POWER FACTOR .75 CONTRACTED POWER FACTOR .90 PENALTY $2000

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APPLICATION & SELECTION OF MOTORS & STARTERS

SUMMARY
NEED TO KNOW
ENVIRONMENT LOAD CHARACTERISTICS PLANT DISTRIBUTION DUTY & LOAD CYCLES

TO SELECT
ENCLOSURE HP & SPEED VOLTAGE EFFICIENCY & POWER FACTOR

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