MMD Design and Consultancy Ltd

A Member of the MMD Group of Companies

Cotes Park Lane, Cotes Park Industrial Estate, Somercotes, Derbyshire, DE55 4NJ

T: +44 (0) 1773 835533 E: sales@mmdsizers.com

F: +44 (0) 1773 835593 W: www.mmdsizers.com

Dynamics of Sizer Operation and Resultant Effect on Electrical

Supply
Figure 1 below illustrates the three-stage breaking action of a Sizer incorporated with a
breaker bar. The mechanical characteristic of the Sizer is interwoven with the electrical
characteristics. On each of the stages, when the Sizer shaft interfaces with the material to
induce stress that will eventually exploit its natural weakness of the material, the electrical
system reacts by demanding peak current (Amperes). If the power supply is poor, then
voltages drop can occur which can lead to a Sizer stall. In order to circumvent this
phenomenon, the power supply is required to be sized appropriately to sustain peak
capabilities of the motor. More also, the speed at which this peak is demanded requires the
electrical supply to react in milliseconds without constituting a voltage drop.

Figure 1: Sizing Three Stage Breaking Action & Effect on Current Consumption

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Figure 2 & 3 below are live data from a UK site in 2013. The Sizer, in this case, was a 750
series Sizer, driven by a 160kW induction motor (281 Amps full load current) and started by
a direct on line (DOL) system. The voltage on the site was 415 VAC. The figures capture
the current (Amps) consumption for 30 minutes of the Sizer operation. Starting current was
in the region of 2798 Amps. However, the utilisation of a Voith fluid coupling and its soft
starting characteristics means that high starting torque from the motor is not actually
required. In fact, the full load torque of the motor is sufficient in starting the entire drivetrain.

Figure 2: Current Consumption of a 160kW Motors/750 Sizer

Figure 3 is a zoom out caption of figure 2, highlighting normal running characteristics of the
Sizer. Although the full load current of the motor is 281 A, when the phenomenon as
described in figure 1 occurs, current demanded can be seen to rise to over 1050Amps
(duration 1.5 seconds). This is normal as the motor slows down in speed to generate more
torque at its break down torque region.

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 Figure 3: Zoomed Out Current Consumption of a 160kW Motor/750 Sizer

Because of the inherent nature of variable frequency drive of rectifying AC to DC and

eventually inverting DC back to AC, delays are introduced into the system. With the
introduction of delays, nuisance Sizer stalls may occur which can circumvent the efficiency
of the Sizer and ultimately create downtime for operation. Direct online starters do not
succumb to this phenomenon, hence our preferred option for using them on Sizer
applications. In addition, the the VFD drive may not able to stand against the frequent peak
overload currents during the peak load on the sizer.
From experience, we have had plethora applications where VFD’s was initially installed on
our Sizer and due to the complications described above, the customers had to revert to
DOL. However, due to confidentiality issues, we cannot divulge information about such
sites. This above is the basis of our insistence on the implementation of DOL’s.

Regards
Prame Siva CEng
Electrical Engineer
MMD Design and Consultancy Ltd

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