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Motor sizing made simple

Machine Design
Robert Repas
Robert Repas
Thu, 2005-01-20 12:30
The proper sizing of three-phase induction motors saves energy and reduces downtime.

Walt Dryburg
Rockwell Automation
Washington, Pa.

A motor driving a load is an energy balancing act. On one side is the

mechanical demand of the turning load. On the other is waste heat
the motor generates turning that load. A small-sized motor that
can't dissipate waste heat fast enough rapidly burns out. Motors
sized too large stay cool but waste energy and money in inefficient
operation. Selecting the optimal size is as easy as following a few
guidelines.

WHAT'S IN A LOAD?
Loads fall into three categories. Those that need constant torque,
those where torque changes gradually, and those where torque
changes abruptly.

Motors are rated by the output power they can produce over a given time period without overheating.
These ratings are on the motor nameplate. Manufacturers build motors with different duty cycles to
match the three load categories. Duty cycle is the ratio of time the motor produces rated power divided
by the total elapsed time. Motors with less than 100% duty cycle must turn off for an amount of time
specified by the duty cycle to cool-down after operating. A motor with a 50% duty cycle must stay off for
the same amount of time it has been on. Motors with less than 100% duty cycle also have a maximum
run-time limit such as 30 min. A 50% duty cycle motor with a 30 min run time means the motor can
operate at its rated output for 30 min. Then it must stay off at least 30 min — for 60 min total time —
before running again.

Constant torque applications: Machines such as centrifugal compressors and extruders have relatively
steady torque requirements. After they start, accelerate, and reach running speed, the torque demand
varies no more than a few percent. To size a motor for this kind of application, match the motor output
rating to the load's torque converted to horsepower:

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where T = torque in lb-ft.

Don't forget the duty cycle! These machines run constantly, so

choose a continuous-duty motor for this type of application.

Variable-torque applications, such as centrifugal pumps and fans,

have a load that varies slowly, often over a range of 20 to 100%. A
motor for these conditions gets sized for the highest continuous load,
which is typically at the highest speed. It is important to know not
only the peak value but also its duration as well. Peak load is the
point that will challenge the motor's ability to turn the load. The
motor must be big enough to manage the peak load and have a duty cycle that outlasts its duration.

Shock load torque can vary wildly and abruptly in equipment such as saws, compactors, and punch
presses. As the load skyrockets the motor slows slightly producing more torque. If the change is extreme,
the load may exceed the motor's break-down torque causing it to stall. The most critical parameter for
these applications is the breakdown figure rather than fullload torque to keep the machine from stalling.
So choose a motor with high breakdown torque.

ESTIMATING HORSEPOWER
Constant load: This is the simplest case. Determine the load from the nameplate on the driven unit, or, if
this is impractical, measure the torque required to turn the load. Choose a motor for which the load is 75
to 100% of the motor's rated capacity. When the load is steady with a long duty cycle it is safe to load the
motor close to its fullload capacity, in the area of 95%. This will optimize efficiency and keep the motor
cost to a minimum.

Variable load: To size a motor for these applications, you must know
the entire load range over which it will operate. Pay particular
attention to the peak load and how long the application stays at peak.
A pump load, for instance, may range from 20 to 100% over its
operating cycle. Use peak load to calculate the motor size because the
motor must be able to drive through the peak demands without
overheating.

BEYOND THE LIMIT

Motor service factors are safety factors. They indicate how much the
motor capacity can be exceeded for short periods without overheating.
For instance, a standard design B motor with a service factor of 1.15
can operate at 15% greater than its rated output without overheating. This is important for motors where
loads vary and may peak slightly above the rated torque. However, since service factors are safety
margins, they are to be used sparingly. A motor that operates continuously above its rated output will
have a short life.

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For variable loads calculate the RMS horsepower requirement and size the motor so the load falls within
75 to 100% of the motor capacity.

GET IT STARTED
Inertia is a load that must be overcome. The
motor must be able to start the load from dead
still, accelerate it to operating speed, and then
continue applying enough torque to maintain
speed. During this startup phase current is five to
seven times that needed at full load.

The process of overcoming high inertia-loads at

startup generates extreme heat. The National
Electrical Manufacturers Association, or NEMA,
has designated four motor design types identified
by the letters A, B, C, and D. Design types specify
various parameters of a motor's startup and
operating qualities, helping to identify which type
of load a motor can handle. Design type A motors
work well with more constant torque applications
and low inertia. Type A motors have medium to
high starting currents that create rapid heat
buildup. The high starting torque of Design D
motors handles the very high-inertia loads with
lower starting current, minimizing heat buildup in
the motor during start. But the lower starting
current means type D motors slip more than type
A. Type D motors slip 5 to 13% compared to the
less than 5% slippage for types A through C.
Industry standard is the type B motor with its
normal starting torque and low starting current.
As the industry standard it is usually the best
economic choice.
Starting torque, also known as locked-rotor torque,
is produced when power is applied to the motor and
the rotor is not yet turning. Starting torque must
exceed load torque for the motor to accelerate the
load.
Pull-up torque is the torque available as the load
accelerates and motor rpm increases. The motor will
stall if the load exceeds this value. Note this value is
less than the starting torque.
Breakdown torque is the maximum torque that a
motor can produce at full speed.
Full-load torque is the maximum torque that the
motor can sustain at operating speed without
overheating.

DON'T OVERLOOK THE CYCLE

Continuous duty is the simplest case. It begins with start-up, followed by long periods of steady
operation where the heat generation and dissipation stabilize, and then ends with shutdown. Motors in
these applications can operate at or near their rated capacities because the temperature rise is
controlled.

Intermittent duty is a more complex problem. Again, heat is the principle villain. Analogous to
commercial airplane landings, the life of a motor is closely related to the number of starts it makes
because it must survive the heat generated at startup. For this reason, motors are limited to the number
of starts and stops they can make in an hour.

Selecting a motor for intermittent duty involves an educated guess. A rule of thumb is that for every 10°C
cooler that a motor operates, its life doubles. So for maximum life you want a motor to run at less than
maximum temperature. A motor sized for peak load alone may burn out rapidly in intermittent duty.

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However, choosing the next larger size motor (say 10 instead of 7.5 hp), brings greater capacity for
coping with frequent starts,

THE ALTITUDE FACTOR

Motors operating at altitudes substantially above sea
level cannot operate at their full service factor because
the air is less dense at high altitudes and does not cool as
well. Derate the motor on a sliding scale to stay within
safe limits of temperature rise. Typically, the service
factor is 1.15 at an altitude of 3,300 ft or below. At 9,000
ft it is derated to 1.00. So when choosing your next
motor, calculate the horsepower load demands,
determine whether conditions call for continuous or
intermittent duty cycle, and pick the best design type A Starting qualities for the four basic motor
through D for the type of load the motor will be driving. designs. Design B is the general-purpose unit,
and is usually less expensive. Because
MAKE CONTACT starting torque is low, it may not be able to
start a high-inertia load. Choose another
National Electrical Manufacturers Association,
design that has adequate low-speed torque.
(703) 841-3200, nema.org
Rockwell Automation, (414) 212-5200,
rockwellautomation.com

Maximum number of starts for selected motors

HP TWO POLE (3,600 rpm) FOUR POLE (1,800 rpm)

A B C A B C

5 8.1 5.7 83 16.3 27 43

10 6.2 11 92 12.5 51 46

20 4.8 21 110 9.6 99 55

50 3.4 39 145 6.8 232 72

100 2.6 92 110 5.2 441 110

A = Maximum number of starts per hour

B = Maximum product of starts per hour
C = Minimum rest time between starts, in seconds

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