Sales training 2014

Part 3
Basic of AC Motors
Induction motor and LSPM motor

Presenter:
Tanja Hedberg

1
Goal

2
Goal

• Know different motor technologies used in Xylem

- Induction motor
- LSPM motor

• Know the different parts of a motor and their purpose

• Be able to freely use the concepts used in motor technology.
• Know different starting methods
• Know the difference in apparent power and active power
• Know efficiency
• Understand the information given in rating and motor charts

3
Flygt motor development heritage

The world’s leading designer and

manufacturer of submersible motors

• Over 50 years of experience

• Cutting edge calculation
programs
• Tested in our own CSA certified
test laboratory
Electrical motors
Construction
Stator leads

Rotor Stator
Rotating part
Stationary part Junction box /
Connection
housing

Terminal
board
Stator End winding
housing
5
Electrical motor parts
Stator consist of…

Laminations

Slots

Insulations

Stator core Phase

Winding insulation

Cables End Winding

insulation

6
Electrical motors

Rotor and shaft units consist of

Laminations

Slots / bars

Squirrel cage (aluminum)

End rings

Skewing

Air gap

7
Electrical motor theory
Induction motor principle
Rotating
stator
• Torque is created by interaction between currents
stator currents and rotor magnetic field
Induced
• rotor
The rotor magnetic field is created by rotor
currents which in turn are induced by the currents
stator currents

Magnetic
field

8
 Flygt’s motor program
• Power range: 0.4 – 800 kW
• Voltages: 110 – 6600 V
• Number of poles: 2 – 16 poles
• Frequencies: 50 & 60 Hz 650
540
• Flygt has about 490 different motors... 430
• And about 3000 stator variants 350
300
• Most of them are 2-4 pole induction
250
motors 210
• Flygt has also line-start permanent 175
magnet motors (4650 and some of the 145
IE3 motors) 125
117

SMAL L MEDI UM LARGE

9
Flygt’s motor denomination
The motor denomination consist of 10 figures and 3 letters grouped according
to below:
Number of poles
Stator outer 2, 4, 6, 8 Rotor
diameter in cm 10, 12, 14, 16,… Second letter A-Z: Rotor execution

1 2 3/4 5 6 Combination of stator + rotor

00 – 00(0) - 00 X X IE, IK: IE3 motor

Core length in cm Stator

First letter A-Z: Stator execution
Example:
• Stator outer diameter approx. 210mm
• Core length approx. 180mm
•
•
4 pole
F: Stator execution 21-18-4FA
• A: Rotor execution

10
Basic electrical terms
Electrical circuit is analytical to water tank as below:
• Current is analogous to the flow rate of water
• Voltage is the pressure pushing that water through a pipe
• Resistance is the width of the pipe

Current
• An electric current is a flow of electric charge, unit is the ampere [A]

Voltage
• Voltage is the electric potential difference between two points, unit is volts [V]
• The SI unit of voltage is volts [V]

Resistance
• Resistance is the hindrance to the flow of charge, unit is ohm [Ω]
• It depends on the length, cross-sectional area and the material of the wire.
11
 Power

Name plate rating =

Rated shaft power  

P2 = Motor output power =

Pump power input =
Shaft power
 
What is rated power?
Power
• Electric power is the consumed power.
• The SI unit of power is the watt [W]
Rated shaft power is
• Mechanical power, output power or
rated shaft power
• Not electrical input power

Rated shaft power is the maximum

Note: this is valid in our products which consist of:
continuous or intermittent power of the pump/mixer + motors !
motor and it depends on:
• Water temperature/Ambient
temperature
• Installation (submersible / dry setup)
• Cooling system (product)
• Type of duty (continuous S1 /
Intermittent periodic S3 duty)
13
Derated power
Why and when
Power should be down rated if there are risk to too high temperatures e.g. in
motor winding (above thermal contacts 125oC or 140oC)
• Increased water (ambient) temperatures
• Other than submersible duty (dry setup without cooling jacket)

To meet customer demands

New rated Rated power
power
2500
Losses [W]

2000 Losses = heat

1500

1000

500

0
0 2 4 6 8 10 12 14 16 18
Power [kW]

15
Efficiency

To calculate a motor's efficiency, the mechanical output

power is divided by the electrical input power:
Pin Pout
Pout Motor
Efficiency: η=
Pin

Some of the power is lost in motor and

Motor losses are mainly due to dissipates as heat
• Resistive losses in windings
• Core losses
• Mechanical losses in bearings, and
aerodynamic losses

Pin - Plosses
Efficiency: η=
Pin

16
Power factor
Power factor or cosφ
P
• The power factor of an AC electrical Q
power system is defined as the ratio S
of the real power flowing to the load,
to the apparent power in the circuit

• It is a dimensionless number
between -1 and 1

S
Q
φ
P
• S is the total / apparent power
• P is the working / real power Stated on the Data plate
• Q is the nonworking / reactive power

17
Number of poles, frequency, slip and speed

Number of p=2 p=4

nsych = 3000 rpm nsych = 1500 rpm
poles:

nsych = f x 60 f is the supply’s frequency (50Hz or 60 Hz)

p/2

2-pole motor rotates about 3000rpm in Europa and 3600rpm in USA

Rotor rotates always with lower speed than the stator's rotating magnetic field
(e.g synchronous speed)

Slip is the difference between synchronous speed and operating speed

18
Winding and number of poles
In asynchronous motor the stator winding sets the number of poles

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12

2 - pole motor 4 - pole motor

180 mechanical = 180 electrical degree 180 mechanical = 360 electrical degree
0.02s / turn 0.04s / turn
50Hz rotor rotates 3000rpm 50Hz rotor rotates 1500rpm

19
Typical torque curve of induction motor
with squirrel cage

Torque is the turning force through a radius and the units is Nm

The torque varies with the speed of the motor when it is accelerate from
zero speed to maximum operating speed.

Mstart Locked rotor torque or starting torque is the

torque motor develop when its starts at zero
speed

Mpull Pull up torque is the minimum torque when

the motor runs zero to full load speed

Mmax Break down torque or maximum torque is

the highest torque available before the torque
decreases to the nominal / rated toque a= speed of motor
b= slip
Mn Rated/nominal torque is the torque required to
produce the rated power of electrical motor at full
load speed.

20
Starting current or locked rotor current
• The typical starting current is about 6-7 times the rated current

• The Flygt motors are designed to withstand the high starting current
and the best startup method for the pump is a direct-on-line (DOL)
start

• If a lower starting current is required some other than DOL start is

needed
• Weak power supply
• Local regulations
• Lower voltage fuse
• Generator backup

21
Electrical supply and voltage variants
Flygt’s electrical motors are designed according to standard IEC 60034-1.

A motor should be capable of performing its rated torque continuously

within some voltage and frequency variations of the electrical supply.
• +/- 10% voltage
• +/- 5% frequency (depends on the voltage)
• Note: need not comply fully with its performance at rated voltage and
frequency.
The rated voltage of a voltage / winding
60 90
Efficiency [%]
variant is 380V. If the motor is used with
Current [A]

55 85
50 80
wrong supply voltage e.g. 500V?
45 75 • Current increases
40 70 • Efficiency decreases
35 65
30 60
25 55
20 50
250 300 350 400 450 500 550
Voltage [V]
• Temperature increases
• Tripping of thermal contacts
or failure
22
Voltage and electrical connections
There are two basic 3 - phase couplings
• Y (star)
• D (delta)

There are also several variants from

basic couplings
• Y//, Yser, D// and Dser
• They are used for different voltages
Examples

Variant 01 may be used with

400V with D-connection
690V with Y-connection

Variant 12 may be used with

230V with D//- connection
380V with Y//- connection
Y// Yser 460V with Dser- connection

23
Single phase induction motor
• Single-phase distribution is used when loads are mostly lighting and heating,
with few large electric motors

• Single-phase power distribution is used especially in rural areas, where the

cost of a three-phase distribution network is high and motor loads are small
and uncommon

• Bigger electrical motor uses 3-phase system, because…

• 1-phase motor can not start at its own. It needs several additional
components to start: start and drift capacitors
• 1-phase motor has bigger losses and lower efficiency than 3-phase
motors
• 1-phase motor can produce only about 70-80% power of 3-phase motor
• 1-phase motor cost more than 3-phase motor with same power

• The biggest single phase motors are about 7.5kW (10HP)

24
Starting methods
Starting methods

1. Direct on line start (DOL) 3. Soft start

• For stable supplies/networks • Reduces the motor voltage resulting
• Most reliable and economical in lower motor torque and starting
starting method current
• The motor voltage is increasing
2. Star-delta (Y/D) starting progressively
• Expensive
• This method can only be used with
delta connected motors
• Starting current reduces to 1/3 of 4. Variable frequency drive (VFD, VSD)
the DOL starting current • Starting current as low as rated
• Increases the starting time current
• Do not work properly in all • Uses only if variable speed and/or
applications process control is desired during the
• Mechanical changeover: the operation
current may not be reduced as • Expensive
required
• Low torque during the Y
connection : The full speed is
maybe not achieved
25
Class H or Class F insulation
• There are several insulation classes Class Max Temp. Max temp.
according to IEC and NEMA [oC] [F]
standards.
A 105 221
E 120 248
• These codes indicate the maximum
B 130 266
temperature the motor insulation
F 155 311
can withstand without failure
H 180 356
• Today most of the standard motors
are according to F or H insulations

• Is isolation H better than isolation

F?
• High safety margin
• Extend stator (insulation) lifetime

26
AC motor types
AC Synchronous motor

Asynchronous
motor

”Hybrid motor” - Traditional synchronous motor - Synkronreluktansmotor

with pole winding och damp - VFD mandatory
windingg

Induction motor

- Short circuit / squirrel-cage - LSPM (line start PM

motor motor)
- Asynchronous motor - Permanent magnet motor - Fractional slot / single
- Slip ring / wound motor
start - VFD mandatory tooth PM motor
- Synchronous motor drift - VFD mandatory

27
LSPM

Line started permanent magnet motor

• Stator
• Similar / same as in induction motor

• Rotor
• AL squirrel cage
• Permanent magnets
• Most suitable pole numbers 4-12

• LSPM prototype (1995)

• 4650 mixer with LSPM motor 25-15-12AS (2007)
• IE3 motors 3085-3153 (2011-2014)

28
Line started permanent magnet motor
Starts like an asychronous motors, runs like a permanent magnet synchronous motors

The start can be divided into two Starting of line start PM motor

sub-processes: 1600

1. Asynchronous start / run-up 1400

The rotor cage provides the 1200

asynchronous run-up torque. 1000

Oscillations are created by

speed [rpm]
800

permanent magnets 600

400

200
2. Synchronisation 0
When the speed is close to -200
synchronous the magnets ”grab 0.00 0.10 0.20 0.30 0.40 0.50

on” to stator magnetic field and time [s]

the rotor current is reduced to

zero

29
Asychronous motor versus PM motor
(3153)

21-18-4AA 21-18-4AS
Asychronous motor LSPM (hybrid)

Power 11kW 11kW

Efficiency 87.9% 92.3%
Advantage + Low rotor losses

+ High power factor

Power factor

Disadvantage - High transient start torque

(oscillation)

- Start problems with high

load or high inertia