Basic Training: Motors, Gears & Drives

BASIC TRAINING
MOTORS, GEARS & DRIVES

INDUSTRIAL-DUTY & COMMERCIAL-DUTY
Elec tric Motors Gear Reduc ers
Gearmotors AC & DC Drives
-1-
Basic Training
Industrial-Duty & Commercial-Duty
Electric Motors Gear Reducers
Gearmotors AC & DC Drives
A Publication O f
Copyright
1999
Price $20.00
Contents
I . I ntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Electric M otor H istory and Principles
I I . General Motor Replacement Guidelines . . . . . . . . . . . .7
I I I . Major Motor Types . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
AC Single Phase
AC Polyphase
D irect Current (D C)
G earm otors
Brakem otors
M otors For Precise M otor Control
I V. Mechanical Considerations . . . . . . . . . . . . . . . . . . . . .16
Enclosures and Environm ent
N EM A Fram e/Shaft Sizes
N EM A Fram e Suffixes
Fram e Prefixes
M ounting
V. Electrical Characteristics
and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Voltage
Phase
Current
Frequency
H orsepow er
Speeds
Insulation Class
Service Factor
Capacitors
Efficiency
Therm al Protection (O verload)
Individual Branch Circuit W iring
Reading a LEESO N M odel N um ber
M ajor M otor Com ponents
-2-
VI . Metric (I EC) Designations . . . . . . . . . . . . . . . . . . . . . .34
VI I . Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Lubrication Procedure
Relubrication Interval Chart
VI I I . Common Motor Types and
Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . .41
I X. Gear Reducers and Gearmotors . . . . . . . . . . . . . . . . .46
Right-Angle W orm G ear Reducers
Parallel-Shaft G ear Reducers
G earm otors
Installation and Application Considerations
Special Environm ental Considerations
G ear Reducer M aintenance
X. Adjustable Speed Drives . . . . . . . . . . . . . . . . . . . . . . .55
D C D rives
AC D rives
O ne PieceM otor/D rive Com binations
AC D rive Application Factors
M otor Considerations W ith AC D rives
Routine M aintenance of Electrical D rives
XI . Engineering Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Tem perature Conversion Table
M echanical Characteristics Table
Electrical Characteristics Table
XI I . Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
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CHAPTER I
Electric Motor History and Principles
The electric m otor in its sim plest term s is a converter of electrical energy
to useful m echanical energy. The electric m otor has played a leading role
in the high productivity of m odern industry, and it is therefore directly
responsible for the high standard of living being enjoyed throughout the
industrialized w orld.
The beginnings of the electric m otor are shrouded in m ystery, but this
m uch seem s clear: The basic principles of electrom agnetic induction w ere
discovered in the early 1800s by O ersted, G auss and Faraday, and this
com bination of Scandinavian, G erm an and English thought gave us the
fundam entals for the electric m otor. In the late 1800s the actual invention
of the alternating current m otor w as m ade by N ikola Tesla, a Serb w ho had
m igrated to the U nited States. O ne m easure of Teslas genius is that he w as
granted m ore than 900 patents in the electrical field. Before Teslas tim e,
direct current m otors had been produced in sm all quantities, but it w as his
developm ent of the versatile and rugged alternating current m otor that
opened a new age of autom ation and industrial productivity.
An electric m otors principle of operation is based on the fact that a cur-
rent-carrying conductor, w hen placed in a m agnetic field, w ill have a force
exerted on the conductor proportional to the current flow ing in the con-
ductor and to the strength of the m agnetic field. In alternating current
m otors, the w indings placed in the lam inated stator core produce the m ag-
netic field. The alum inum bars in the lam inated rotor core are the current-
carrying conductors upon w hich the force acts. The resultant action is the
rotary m otion of the rotor and shaft, w hich can then be coupled to various
devices to be driven and produce the output.
M any types of m otors are produced today. U ndoubtedly, the m ost com -
m on are alternating current induction m otors. The term induction
derives from the transference of pow er from the stator to the rotor through
electrom agnetic induction. N o slip rings or brushes are required since the
load currents in the rotor conductors are induced by transform er action.
The induction m otor is, in effect, a transform er - w ith the stator w inding
being the prim ary w inding and the rotor bars and end rings being the m ov-
able secondary m em bers.
B oth single-phase and polyphase A C m otors are produced by
LEESO N and m any other m anufacturers. In polyphase m otors, the place-
-4-
m ent of the phase w inding groups in conjunction w ith the phase sequence
of the pow er supply line produces a rotating field around the rotor surface.
The rotor tends to follow this rotating field w ith a rotational speed that
varies inversely w ith the num ber of poles w ound into the stator. Single-
phase m otors do not produce a rotating field at a standstill, so a starter
w inding is added to give the effect of a polyphase rotating field. O nce the
m otor is running, the start w inding can be cut out of the circuit, and the
m otor w ill continue to run on a rotating field that now exists due to the
m otion of the rotor interacting w ith the single-phase stator m agnetic field.
In recent years, the developm ent of pow er sem iconductors and m icro-
processors has brought efficient adjustable speed control to AC m otors
through the use of inverter drives. Through this technology, the m ost
recent designs of so-called pulse w idth m odulated AC drives are capable
of speed and torque regulation that equals or closely approxim ates direct
current system s.
LEESO N Electric also produces perm anent-m agnet direct current m otors.
The D C m otor is the oldest m em ber of the electric m otor fam ily. Recent
technological breakthroughs in m agnetic m aterials, as w ell as solid state
electronic controls and high-pow er-density rechargeable batteries, have all
revitalized the versatile D C m otor.
D C m otors have extrem ely high torque capabilities and can be used in
conjunction w ith relatively sim ple solid state control devices to give pro-
gram m ed acceleration and deceleration over a w ide range of selected
speeds. Because the speed of a D C m otor is not dependent on the num -
ber of poles, there is great versatility for any constant or variable speed
requirem ent.
In m ost com m on D C m otors, the m agnetic field is produced by high-
strength perm anent m agnets, w hich have replaced traditional field coil
w indings. The m agnets require no current from the pow er supply. This
im proves m otor efficiency and reduces internal heating. In addition, the
reduced current draw enhances the life of batteries used as pow er supplies
in m obile or rem ote applications.
Both AC and D C m otors m ust be m anufactured w ith a great deal of preci-
sion in order to operate properly. LEESO N and other m ajor m anufacturers
use lam inated stator, rotor and arm ature cores to reduce energy losses and
heat in the m otor. Rotors for AC m otors are heat treated to separate the
alum inum bars from the rotors m agnetic lam inations. Shaft and bearing
tolerances m ust be held to ten thousandths of an inch. The w hole struc-
ture of the m otor m ust be rigid to reduce vibration and noise. The stator
-5-
insulation and coil w inding m ust be done in a precise m anner to avoid
dam aging the w ire insulation or ground insulation. And m ountings m usts
m eet exacting dim ensions. This is especially true for m otors w ith N EM A C
face m ountings, w hich are used for direct coupling to speed reducers,
pum ps and other devices.
The electric m otor is, of course, the very heart of any m achine it drives. If
the m otor does not run, the m achine or device w ill not function. The
im portance and scope of the electric m otor in m odern life is attested to by
the fact that electric m otors, num bering countless m illions in total, convert
m ore energy than do all our passenger autom obiles. Electric m otors are
m uch m ore efficient in energy conversion than autom obiles, but they are
such a large factor in the total energy picture that renew ed interest is being
show n in m otor perform ance. Todays industrial m otors have energy con-
version efficiency exceeding 95% in larger horsepow ers.
This efficiency, com bined w ith unsurpassed durability and reliability, w ill
continue to m ake electric m otors the prim e m oversof choice for decades
to com e.
-6-
The Doerr family, whose members founded and continue to own and operate
LEESON Electric, has a three-generation history in electric motor manufacturing.
Shown at left is a motor from the early 1900s, made by St.Louis Electrical Works,
later Baldor Electric. At right is a motor from the late 1930s, made by Electro
Machines, later Doerr Electric and now part of Emerson Electric.
CHAPTER II
General Motor Replacement Guidelines
Electric m otors are the versatile w orkhorses of industry. In m any applica-
tions, m otors from a num ber of m anufacturers can be used.
M ajor m otor m anufacturers today m ake every effort to m axim ize inter-
changeability, m echanically and electrically, so that com prom ise does not
interfere w ith reliability and safety standards. H ow ever, no m anufacturer
can be responsible for m isapplication. If you are not certain of a replace-
m ent condition, contact a qualified m otor distributor, sales office or service
center.
Safety Precautions
U se safe practices w hen handling, lifting, installing, operating, and
m aintaining m otors and related equipm ent.
Install m otors and related equipm ent in accordance w ith the N ational
Electrical Code (N EC) local electrical safety codes and practices and,
w hen applicable, the O ccupational Safety and H ealth Act (O SH A).
G round m otors securely. M ake sure that grounding w ires and devices
are, in fact, properly grounded.
Before servicing or w orking near m otor-driven equipm ent, disconnect the
pow er source from the m otor and accessories.
Selection
Identifying a m otor for replacem ent purposes or specifying a m otor for
new applications can be done easily if the correct inform ation is know n.
This includes:
N am eplate D ata
M echanical Characteristics
M otor Types
Electrical Characteristics and Connections
-7-
Failure to ground a motor properly
may cause serious injury.
M uch of this inform ation consists of standards defined by the N ational
Electrical M anufacturers Association (N EM A). These standards are w idely
used throughout N orth Am erica. In other parts of the w orld, the standards
of the International Electrotechnical Com m ission (IEC) are m ost often
used.
Nameplate
N am eplate data is the critical first step in determ ining m otor replacem ent.
M uch of the inform ation needed can generally be obtained from the nam e-
plate. Record all nam eplate inform ation; it can save tim e and confusion.
I mportant Nameplate Data
Catalog num ber.
M otor m odel num ber.
Fram e.
Type (classification varies from m anufacturer to m anufacturer).
Phase - single, three or direct current.
H P - horsepow er at rated full load speed.
H Z - frequency in cycles per second. U sually 60 hz in U nited States,
50 hz overseas.
RPM - revolutions per m inute.
-8-
Voltage.
Am perage (F.L.A.) - full load m otor current.
M axim um am bient tem perature in centigrade - usually +40C (104F).
D uty - m ost m otors are rated continuous. Som e applications, how ev-
er, m ay use m otors designed for interm ittent, special, 15, 30 or 60
m inute duty.
N EM A electrical design - B, C and D are m ost com m on. D esign letter
represents the torque characteristics of the m otor.
Insulation class - standard insulation classes are B, F, and H . N EM A has
established safe m axim um operating tem peratures for m otors. This
m axim um tem perature is the sum of the m axim um am bient and m ax-
im um rise at m axim um am bient.
Code - indicates locked rotor kVA per horsepow er.
Service factor - a m easure of continuous overload capacity.
-9-
CHAPTER III
Major Motor Types
Alternating current (AC) induction m otors are divided into tw o electrical
categories based on their pow er source single phase and polyphase
(three phase).
AC Single Phase Types
Types of single-phase m otors are distinguished m ostly by the w ay they are
started and the torque they develop.
Shaded Pole m otors have low starting torque, low cost, low efficiency,
and no capacitors. There is no start sw itch. These m otors are used on sm all
direct drive fans and blow ers found in hom es. Shaded pole m otors should
not be used to replace other types of single-phase m otors.
PSC (Permanent Split Capacitor) m otors
have applications sim ilar to shaded pole,
except m uch higher efficiency, low er current
(50% - 60% less), and higher horsepow er capa-
bility. PSC m otors have a run capacitor in the
circuit at all tim es. They can be used to replace
shaded pole m otors for m ore efficient opera-
tion and can be used for fan-on-shaft fan appli-
cations, but not for belted fans due to the low
starting torque.
Split Phase m otors have m oderate to low
starting torque (100% - 125% of full load), high
starting current, no capacitor, and a starting
sw itch to drop out the start w inding w hen the
m otor reaches approxim ately 75% of its operat-
ing speed. They are used on easy-to-start belt
drive fans and blow ers, as w ell as light-start
pum p applications.
-10-
PSC circuit diagram
Capacitor Start m otors are designed in both m oderate and high starting
torque types w ith both having m oderate starting current, high breakdow n
torques.
M oderate-torque m otors are used on applications in w hich starting requires
torques of 175% or less or on light loads such as fans, blow ers, and light-
start pum ps. H igh-torque m otors have starting torques in excess of 300%
of full load and are used on com pressors, industrial, com m ercial and farm
equipm ent. Capacitor start m otors use a start capacitor and a start sw itch,
w hich takes the capacitor and start w inding out of the circuit w hen m otor
reaches approxim ately 75% of its operating speed.
Capacitor Start/Capacitor Run m otors have applications and perfor-
m ance sim ilar to capacitor start except for the addition of a run capacitor
(w hich stays in circuit) for higher efficiency and reduced running am per-
age. G enerally, start/ capacitor run m otors are used for 3 H P and larger sin-
gle-phase applications.
-11-
On industrial duty
motors, capacitors are
usually protected by metal
cases attached to the
motor frame.This capaci-
tor start/capacitor run
motor has two cases.
Cap start circuit diagram
AC Polyphase
Polyphase (three-phase) induction
m otors have a high starting torque, pow er
factor, high efficiency, and low current.
They do not use a sw itch, capacitor,
relays, etc., and are suitable for larger
com m ercial and industrial applications.
Polyphase induction m otors are specified by their electrical design type: A,
B, C, D or E, as defined by the N ational Electrical M anufacturers
Association (N EM A). These designs are suited to particular classes of
applications based upon the load requirem ents typical of each class.
The table on the next page can be used to help guide w hich design type
to select based on application requirem ents.
Because of their w idespread use throughout industry and because their
characteristics lend them selves to high efficiencies, m any types of general-
purpose three-phase m otors are required to m eet m andated efficiency lev-
els under the U .S. Energy Policy Act. Included in the m andates are N EM A
D esign B, T fram e, foot-m ounted m otors from 1-200 H P.
-12-
A heavy-duty polyphase motor with cast-iron frame.
-13-
The follow ing table can be used to help guide w hich design type should be selected:
NEMA Electrical Design Standards
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p
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d

w
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-
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m
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F
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,

b
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,

c
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p
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p
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o
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,

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c
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w
Direct Current (DC)
Another com m only used m otor in industrial applications is the direct cur-
rent m otor. It is often used in applications w here adjustable speed control
is required.
Perm anent m agnet D C designs are generally used for m otors that produce
less than 5 H P. Larger horsepow er applications use shunt-w ound direct
current m otors.
Both designs have linear speed/torque characteristics over the entire speed
range. SCR rated m otors those designed for use w ith com m on solid-state
speed controls feature high starting torque for heavy load applications
and reversing capabilities, and com plem entary active m aterial to com pen-
sate for the additional heating caused by the rectified AC input. D esigns
are also available for use on generated low -voltage D C pow er or rem ote
applications requiring battery pow er.
Gearmotors
A gearm otor is m ade up of an elec-
tric m otor, either D C or AC, com -
bined w ith a geared speed reducer.
Spur, helical or w orm gears m ay be
used in single or m ultiple stages.
The configuration m ay be either
that of a parallel shaft, em erging
from the front of the m otor, or a
right-angle shaft. G earm otors are
often rated in input horsepow er;
how ever, output torque, com m only
m easured in inch-pounds, and out-
put speed are the critical values.
-14-
DC motors can be operated
from rectified alternating cur-
rent of from low-voltage bat-
tery or generator source.This
is a low-voltage design, which
includes external connection
lugs for the input power.With
the rear endshield removed,
as in this view, the brush
assemblies and commutator
that form a DC motors elec-
trical heart are clearly visible.
Speed reduction
gearing is visible in this cutaway view of a
parallel-shaft gearmotor.Shown is a small,
sub-fractional horsepower gearmotor.
G earm otors m ay be either integral, m eaning the gear reducer and m otor
share a com m on shaft, or they m ay be created from a separate gear reduc-
er and m otor, coupled together. Integral gearm otors are com m on in sub-
fractional horsepow er sizes; separate reducers and m otors are m ore often
the case in fractional and integral horsepow ers. For m ore on gear reduc-
ers and gearm otors, see Chapter IX.
Brakemotors
A brakem otor is a pre-connected package of industrial-duty m otor and fail-
safe, stop-and-hold spring-set brake. In case of pow er failure, the brake
sets, holding the load in position. Brakem otors are com m only used on
hoists or other lifting devices. Brake features can also be added to standard
m otors through conversion kits that attach to the shaft end of either fan-
cooled or open m otor.
Motors for Precise Motion Control
These m otors are alw ays part of integrated m otor-and-controller system s
that provide extrem e accuracy in positioning and speed. Com m on appli-
cations include com puter-controlled m anufacturing m achines and process
equipm ent. Servom otors are the largest category of m otors for precision
m otion control. AC, D C brush-type, and brushless D C versions are avail-
able. Closed-loop control system s, com m on w ith servom otors, use feed-
back devices to provide inform ation to a digital controller, w hich in turn
drives the m otor. In som e cases, a tachom eter m ay be used for velocity
control and an encoder for position inform ation. In other cases, a resolver
provides both position and velocity feedback.
Step (or stepper) m otors, w hich m ove in fixed increm ents instead of rotat-
ing continuously, provide another m eans of precision m otion control.
U sually, they are part of open-loop control system s, m eaning there are no
feedback devices.
-15-
A three-phase brakemotor.Note the
brake on the fan end.Like many
brakemotors, this model has a
NEMA C face for direct mounting to
the equipment to be driven.
CHAPTER IV
Mechanical Considerations
Enclosures and Environment
Open Drip Proof (ODP) m otors have venting
in the end fram e and/or m ain fram e, situated to
prevent drops of liquid from falling into the
m otor w ithin a 15 angle from vertical. These
m otors are designed for use in areas that are rea-
sonably dry, clean, w ell-ventilated, and usually
indoors. If installed outdoors, O D P m otors
should be protected w ith a cover that does not
restrict air flow .
Totally Enclosed Non-Ventilated (TENV) m otors have no vent open-
ings. They are tightly enclosed to prevent the free exchange of air, but are
not air tight. TEN V m otors have no cooling fan and rely on convection for
cooling. They are suitable for use w here exposed to dirt or dam pness, but
not for hazardous locations or applications having frequent hosedow ns.
Totally Enclosed Fan Cooled (TEFC) m otors
are the sam e as TEN V except they have an exter-
nal fan as an integral part of the m otor to provide
cooling by blow ing air over the outside fram e.
Totally Enclosed Air Over m otors are specifical-
ly designed to be used w ithin the airflow of the
fan or blow er they are driving. This provides an im portant part of the
m otors cooling.
Totally Enclosed Hostile and Severe Environment m otors are designed
for use in extrem ely m oist or chem ical environm ents, but not for haz-
ardous locations.
-16-
Explosion Proof m otors m eet U nder-w rit-
ers Laboratories or CSA standards for use in
the hazardous (explosive) locations show n
by the U L/CSA label on the m otor. The m otor
user m ust specify the explosion proof m otor
required. Locations are considered haz-
ardous because the atm osphere contains or
m ay contain gas, vapor, or dust in explosive
quantities. The N ational Electrical Code (N EC) divides these locations into
classes and groups according to the type of explosive agent. The follow -
ing list has som e of the agents in each classification. For a com plete list,
see Article 500 of the N ational Electrical Code.
Class I (Gases, Vapors)
G roup A Acetylene
G roup B Butadiene, ethylene oxide, hydrogen,
propylene oxide
G roup C Acetaldehyde, cyclopropane, diethlether,
ethylene, isoprene
G roup D Acetone, acrylonitrile, am m onia, benzene,
butane, ethylene dichloride, gasoline,
hexane, m ethane, m ethanol, naphtha,
propane, propylene, styrene, toluene, vinyl
acetate, vinyl chloride, xylene
Class I I (Combustible Dusts)
G roup E Alum inum , m agnesium and other m etal
dusts w ith sim ilar characteristics
G roup F Carbon black, coke or coal dust
G roup G Flour, starch or grain dust
The m otor am bient tem perature is not to exceed +40C or -25C unless the
m otor nam eplate specifically perm its another value. LEESO N explosion
proof m otors are approved for all classes noted except
Class I, G roups A & B .
-17-
NEMA Frame/Shaft Sizes
Fram e num bers are not intended to indicate electrical characteristics such
as horsepow er. H ow ever, as a fram e num ber becom es higher so in gener-
al does the physical size of the m otor and the horsepow er. There are m any
m otors of the sam e horsepow er built in different fram es. N EM A (N ational
Electrical M anufacturers Association) fram e size refers to m ounting only
and has no direct bearing on the m otor body diam eter.
In any standard fram e num ber designation there are either tw o or three
num bers. Typical exam ples are fram e num bers 48, 56, 145, and 215. The
fram e num ber relates to the D dim ension (distance from center of shaft
to center bottom of m ount). For exam ple, in the tw o-digit 56 fram e, the
D dim ension is 3
1
/
2
, 56 divided by 16 = 3
1
/
2
. For the D dim ension of
a three-digit fram e num ber, consider only the first tw o digits and use the
divisor 4. In fram e num ber 145, for exam ple, the first tw o digits divided
by the constant 4 is equal to the D dim ension. 14 divided by 4 = 3
1
/
2
.
Sim ilarly, the D dim ension of a 213 fram e m otor is 5
1
/
4
, 21 divided by
4 = 5
1
/
4
.
By N EM A definition, tw o-digit fram e num bers are fractional fram es even
though 1 H P or larger m otors m ay be built in them . Three-digit fram e num -
bers are by definition integral fram es. The third num eral indicates the dis-
tance betw een the m ounting holes parallel to the base. It has no signifi-
cance in a footless m otor.
A sum m ary of N EM A standard dim ensions is on the facing page.
-18-
T
A
P
K
E
Y
*
*
1
/
4
-
2
0
3
/
6
4

F
l
a
t
1
/
4
-
2
0
3
/
6
4

F
l
a
t
3
/
8
-
1
6
3
/
1
6
3
/
8
-
1
6
3
/
1
6
1
/
2
-
1
3
5
/
1
6
1
/
2
-
1
3
5
/
1
6
1
/
2
-
1
3
3
/
8
3
/
8
1
/
2

1
3
1
/
2
3
/
8
1
/
2
5
/
8

1
1
1
/
2
1
/
2
5
/
8

1
1
5
/
8
1
/
2
5
/
8
1
/
2
5
/
8

1
1
3
/
4
1
/
2
3
/
4
5
/
8
5
/
8

1
1
7
/
8
7
/
8
7
/
8
N
E
M
A
F
r
a
m
e
D
E
F
H
N
O
P
U
N
-
W
A
A
A
B
A
H
A
J
A
K
B
A
B
B
B
D
X
O
X
P
S
i
z
e
L
4
2
2

5
/
8
1

3
/
4
2
7
/
3
2
1

1
/
4
5

1
/
1
6
4

7
/
8
3
/
8
1

1
/
8
3
/
8
4

1
/
2
1

5
/
1
6
3

3
/
4
3
2

1
/
1
6
1
/
8
4

7
/
8
1

5
/
8
5

1
/
8
4
8
3
2

1
/
8
1

3
/
8
1

9
/
1
6
5

1
3
/
1
6
5

1
9
/
3
2
1
/
2
1

1
/
2
1
/
2
4

7
/
8
1

1
1
/
1
6
3

3
/
4
3
2

1
/
2
1
/
8
5
2

1
/
4
5

7
/
8
S
5
6
6

5
/
1
6
5

1
9
/
3
2
4

7
/
8
5

7
/
8
5
6
3

1
/
2
2

7
/
1
6
1

1
/
2
1

1
5
/
1
6
6

1
3
/
1
6
6

1
9
/
3
2
5
/
8
1

7
/
8
1
/
2
5

5
/
1
6
2

1
/
1
6
5

7
/
8
4

1
/
2
2

3
/
4
1
/
8
6

1
/
2
2

1
/
4
7

5
/
3
2
1
4
3
T
2
1
4
5
T
3

1
/
2
2

3
/
4
2

1
/
2
1
1
/
3
2
2

3
/
8
6

1
3
/
1
6
6

1
9
/
3
2
7
/
8
2

1
/
4
3
/
4
5

5
/
1
6
2

1
/
8
5

7
/
8
4

1
/
2
*
2

1
/
4
1
/
8
6

1
/
2
2

1
/
4
7

5
/
3
2
1
8
2
T
2

1
/
4
1
8
4
T
4

1
/
2
3

3
/
4
2

3
/
4
1
3
/
3
2
2

7
/
8
8

3
/
4
8

1
5
/
3
2
1

1
/
8
2

3
/
4
3
/
4
6

3
/
8
2

5
/
8
7

1
/
4
8

1
/
2
*
2

3
/
4
1
/
4
8

7
/
8
2

1
/
4
9

3
/
3
2
S
2
1
3
T
2

3
/
4
3

1
/
2
9

1
5
/
1
6
8

1
5
/
3
2
3
/
4
6

3
/
8
8

7
/
8
9

3
/
3
2
2
1
3
T
5

1
/
4
4

1
/
4
2

3
/
4
1
3
/
3
2
1

3
/
8
3

3
/
8
3

1
/
8
7

1
/
4
8

1
/
2
*
3

1
/
2
1
/
4
2

1
/
4
2
1
5
T
3

1
/
2
1
0

1
1
/
1
6
1
0

1
3
/
1
6
1
8

5
/
1
6
9
1
1

3
/
3
2
2
5
4
T
4

1
/
8
2
5
6
T
6

1
/
4
5
5
1
7
/
3
2
1
2

1
5
/
1
6
1
3

1
/
4
1

5
/
8
4
1

1
/
4
1
1

5
/
8
3

3
/
4
7

1
/
4
8

1
/
2
*
4

1
/
4
1
/
4
9

5
/
8
1
2

7
/
8
2
8
4
T
S
1

5
/
8
3

1
/
4
3
2
8
4
T
7
5

1
/
2
4

3
/
4
1
7
/
3
2
1
4

1
/
2
1
4

3
/
4
1

7
/
8
4

5
/
8
1

1
/
2
1
1

3
/
4
4

3
/
8
9
1
0

1
/
2
4

3
/
4
1
/
4
1
1
1
4

1
/
2
2
8
6
T
S
1

5
/
8
3

1
/
4
3
2
8
6
T
5

1
/
2
1

7
/
8
4

5
/
8
4

3
/
8
3
2
4
T
S
1

7
/
8
3

3
/
4
3

1
/
2
3
2
4
T
8
6

1
/
4
5

1
/
4
2
1
/
3
2
1
5

3
/
4
1
5

3
/
4
2

1
/
8
5

1
/
4
2
1
3

1
/
2
5
1
1
1
2

1
/
2
5

1
/
4
1
/
4
1
3

3
/
8
1
5

3
/
4
3
2
6
T
S
6
1

7
/
8
3

3
/
4
3

1
/
2
3
2
6
T
2

1
/
8
5

1
/
4
5
3
6
4
T
S
1

7
/
8
3

3
/
4
3

1
/
2
3
6
4
T
9
7
5

5
/
8
2
1
/
3
2
1
7

1
3
/
1
6
1
7

3
/
8
2

3
/
8
5

7
/
8
3
1
5

7
/
1
6
5

5
/
8
1
1
1
2

1
/
2
5

7
/
8
1
/
4
1
4
1
7
/
3
/
4
3
6
5
T
S
6

1
/
8
1

7
/
8
3

3
/
4
3

1
/
2
3
6
5
T
2

3
/
8
5

7
/
8
5

5
/
8
4
0
4
T
S
2

1
/
8
4

1
/
4
4
4
0
4
T
1
0
8
6

1
/
8
1
3
/
1
6
1
9

5
/
1
6
1
9

1
/
8
2

7
/
8
7

1
/
4
3
1
6

5
/
1
6
7
1
1
1
2

1
/
2
6

5
/
8
1
/
4
1
5

1
/
2
1
9

3
/
8
4
0
5
T
S
6

7
/
8
2

1
/
8
4

1
/
4
4
4
0
5
T
2

7
/
8
7

1
/
4
7
4
4
4
T
S
7

1
/
4
2

3
/
8
4

3
/
4
4
4
4
T
1
1
9
7

1
/
4
1
3
/
1
6
2
2

1
/
4
2
2
8

1
/
2
3
2
1

1
1
/
1
6
8

1
/
4
1
4
1
6
7

1
/
2
1
/
4
1
8
1
9

3
/
8
4
4
5
T
8

1
/
4
3

3
/
8
8

1
/
2
4
4
7
T
Z
1
0
1
0

1
/
8
9
/
3
2
S
l
o
t
1
1
/
3
2
S
l
o
t
1
1
/
3
2
S
l
o
t
Motor Frame Dimensions
(inches)
-19-
S
h
a
d
e
d

a
r
e
a

d
e
n
o
t
e
s

d
i
m
e
n
s
i
o
n
s

e
s
t
a
b
l
i
s
h
e
d

b
y

N
E
M
A

s
t
a
n
d
a
r
d

M
G
-
1
.

O
t
h
e
r

d
i
m
e
n
s
i
o
n
s

w
i
l
l

v
a
r
y

a
m
o
n
g

m
a
n
u
f
a
c
-
t
u
r
e
s
.
NEMA Frame Suffixes
C = N EM A C face m ounting (specify w ith or w ithout rigid base)
D = N EM A D flange m ounting (specify w ith or w ithout
rigid base)
H = Indicates a fram e w ith a rigid base having an F dim ension
larger than that of the sam e fram e w ithout the suffix H . For
exam ple, com bination 56H base m otors have m ounting
holes for N EM A 56 and N EM A 143-5T and a standard
N EM A 56 shaft
J = N EM A C face, threaded shaft pum p m otor
JM = Close-coupled pum p m otor w ith specific dim ensions and
bearings
JP = Close-coupled pum p m otor w ith specific dim ensions and
bearings
M = 6
3
/
4
flange (oil burner)
N = 7
1
/
4
flange (oil burner)
T,TS = Integral horsepow er N EM A standard shaft dim ensions if
no additional letters follow the Tor TS.
TS = M otor w ith N EM A standard short shaft for belt-
driven loads.
Y = N on-N EM A standard m ount; a draw ing is required to be
sure of dim ensions. Can indicate a special base, face or
flange.
Z = N on-N EM A standard shaft; a draw ing is required to be sure
of dim ensions.
Frame Prefixes
Letters or num bers appearing in front of the N EM A fram e num ber are those
of the m anufacturer. They have no N EM A fram e significance. The signifi-
cance from one m anufacturer to another w ill vary. For exam ple, the letter
in front of LEESO N s fram e num ber, L56, indicates the overall length of the
m otor.
Mounting
U nless specified otherw ise, m otors can be m ounted in any position or any
angle. H ow ever, unless a drip cover is used for shaft-up or shaft-dow n
applications, drip proof m otors m ust be m ounted in the horizontal or side-
w all position to m eet the enclosure definition. M ount m otor securely to the
m ounting base of equipm ent or to a rigid, flat surface, preferably m etallic.
-20-
Types of Mounts
Rigid base is bolted, w elded, or cast on m ain
fram e and allow s m otor to be rigidly m ounted on
equipm ent.
Resilient base has isolation or resilient rings
betw een m otor m ounting hubs and base to
absorb vibrations and noise. A conductor is
im bedded in the ring to com plete the circuit for
grounding purposes.
NEMA C face mount is a m achined face w ith a
pilot on the shaft end w hich allow s direct m ount-
ing w ith the pum p or other direct coupled equip-
m ent. Bolts pass through m ounted part to thread-
ed hole in the m otor face.
NEMA D flange mount is a m achined flange
w ith rabbet for m ountings. Bolts pass through
m otor flange to a threaded hole in the m ounted
part. N EM A C face m otors are by far the m ost
popular and m ost readily available. N EM A D
flange kits are stocked by som e m anufacturers,
including LEESO N .
Type M or N mount has special flange for direct
attachm ent to fuel atom izing pum p on an oil
burner. In recent years, this type of m ounting has
becom e w idely used on auger drives in poultry
feeders.
Extended through-bolt m otors have bolts pro-
truding from the front or rear of the m otor by
w hich it is m ounted. This is usually used on sm all
direct drive fans or blow ers.
-21-
Application Mounting
For direct-coupled applications, align shaft and coupling carefully, using
shim s as required under m otor base. U se a flexible coupling, if possible,
but not as a substitute for good alignm ent practices.
Pulleys, sheaves, sprockets and gears should be generally m ounted as
close as possible to the bearing on the m otor shaft, thereby lessening the
bearing load.
The center point of the belt, or system of V-belts, should not be beyond
the end of the m otor shaft.
The inner edge of the sheave or pulley rim should not be closer to the
bearing than the shoulder on the shaft, but should be as close to this point
as possible.
The outer edge of a chain sprocket or gear should not extend beyond the
end of the m otor shaft.
To obtain the m inim um pitch diam eters for flat-belt, tim ing-belt, chain, and
gear drives, the m ultiplier given in the follow ing table should be applied
to the narrow V-belt sheave pitch diam eters in N EM A M G 1-14.444 for
alternating current, general-purpose m otors, or to the V-belt sheave pitch
diam eters as determ ined from N EM A M G 1-14.67 for industrial direct cur-
rent m otors.
D rive M ultiplier
Flat belt* 1.33
Tim ing belt+ 0.9
Chain sprocket 0.7
Spur gear 0.75
H elical gear 0.85
* This m ultiplier is intended for use w ith conventional single-ply flat belts.
W hen other than single-ply flat belts are used, the use of a larger m ultipli-
er is recom m ended.
+ It is often necessary to install tim ing belts w ith a snug fit. H ow ever, ten-
sion should be no m ore than that necessary to avoid belt slap or tooth
jum ping.
-22-
Belt Tensioning
M anufacturers of belts can provide recom m ended tensioning values and
instrum ents for precisely determ ining belt tension. Particularly in very
high-speed, very high-torque or very high-horsepow er applications, critical
belt tensioning can be im portant. For m ost industrial applications, how ev-
er, these general belt tensioning procedures are usually adequate:
1. The best tension is typically the low est at w hich the belt w ill not slip
under peak load.
2. O ver-tensioning w ill shorten belt and bearing life.
3. After installing a new belt, check the tension often during the first 24
to 48 operating hours, and re-tension as necessary.
4. Periodically inspect and re-tension the belt.
As a general rule, the correct belt tension can be gauged by deflecting the
belt at m id-span w ith your thum b w hile the m otor is stopped. You should
be able to deflect approxim ately 1/2 inch w ith light to m oderate pressure
on single-ribbed belts. M ultiple ribs w ill require additional pressure.
Tw o m ethods of checking belt tension w hile the m otor is operating include
visually assessing w hether there is any belt flutter, or listening for belt
squeal. Either can occur as a result of inadequate tension.
-23-
CHAPTER V
Electrical Characteristics and Connections
Voltage, frequency and phase of pow er supply should be consistent w ith
the m otor nam eplate rating. A m otor w ill operate satisfactorily on voltage
w ithin 10% of nam eplate value, or frequency w ithin 5% , or com bined volt-
age and frequency variation not to exceed 10% .
Voltage
Com m on 60 hz voltages for single-phase m otors are 115 volt, 230 volt, and
115/230 volt.
Com m on 60 hz voltage for three-phase m otors are 230 volt, 460 volt and
230/460 volt. Tw o hundred volt and 575 volt m otors are som etim es
encountered. In prior N EM A standards these voltages w ere listed as 208 or
220/440 or 550 volts. M otors w ith these voltages on the nam eplate can
safely be replaced by m otors having the current standard m arkings of 200
or 208, 230/460 or 575 volts, respectively.
M otors rated 115/208-230 volt and 208-230/460 volt, in m ost cases, w ill
operate satisfactorily at 208 volts, but the torque w ill be 20% - 25% low er.
O perating below 208 volts m ay require a 208 volt (or 200 volt) m otor or
the use of the next higher horsepow er, standard voltage m otor.
Phase
Single-phase m otors account for up to 80% of the m otors used in the
U nited States but are used m ostly in hom es and in auxiliary low -horse-
pow er industrial applications such as fans and on farm s.
Three-phase m otors are generally used on larger com m ercial and industri-
al equipm ent.
Current (Amps)
In com paring m otor types, the full load am ps and/or service factor am ps
are key param eters for determ ining the proper loading on the m otor. For
exam ple, never replace a PSC type m otor w ith a shaded pole type as the
latters am ps w ill norm ally be 50% - 60% higher. Com pare PSC w ith PSC,
capacitor start w ith capacitor start, and so forth.
-24-
Hertz / Frequency
In N orth Am erica 60 hz (cycles) is the com m on pow er source. H ow ever,
m ost of the rest of the w orld is supplied w ith 50 hz pow er.
Horsepower
Exactly 746 w atts of electrical pow er w ill produce 1 H P if a m otor could
operate at 100% efficiency, but of course no m otor is 100% efficient. A 1
H P m otor operating at 84% efficiency w ill have a total w att consum ption
of 888 w atts. This am ounts to 746 w atts of usable pow er and 142 w atts loss
due to heat, friction, etc. (888 x .84 = 746 = 1 H P).
H orsepow er can also be calculated if torque is know n, using one of these
form ulas:
Torque (lb/ft) x RPM
H P =
5,250
Torque (oz/ft) x RPM
H P =
84,000
Torque (in/lbs) x RPM
H P =
63,000
Speeds
The approxim ate RPM at rated load for sm all and m edium m otors operat-
ing at 60 hz and 50 hz at rated volts are as follow s:
60 hz 50 hz Synch. Speed
2 Pole 3450 2850 3600
4 Pole 1725 1425 1800
6 Pole 1140 950 1200
8 Pole 850 700 900
Synchronous speed (no-load) can be determ ined by this form ula:
Frequency (H ertz) x 120
N um ber of Poles
-25-
Insulation Class
Insulation system s are rated by standard N EM A classifications according to
m axim um allow able operating tem peratures. They are as follow s:
Class M axim um Allow ed Tem perature*
A 105C (221F)
B 130C (266F)
F 155C (311F)
H 180C (356F)
* Motor temperature rise plus maximum ambient
G enerally, replace a m otor w ith one having an equal or higher insulation
class. Replacem ent w ith one of low er tem perature rating could result in
prem ature failure of the m otor. Each 10C rise above these ratings can
reduce the m otors service life by one half.
Service Factor
The service factor (SF) is a m easure of continuous overload capacity at
w hich a m otor can operate w ithout overload or dam age, provided the
other design param eters such as rated voltage, frequency and am bient tem -
perature are w ithin norm s. Exam ple: a 3/4 H P m otor w ith a 1.15 SF can
operate at .86 H P, (.75 H P x 1.15 = .862 H P) w ithout overheating or oth-
erw ise dam aging the m otor if rated voltage and frequency are supplied at
the m otors leads. Som e m otors, including m ost LEESO N m otors, have
higher service factors than the N EM A standard.
It is not uncom m on for the original equipm ent m anufacturer (O EM ) to load
the m otor to its m axim um load capability (service factor). For this reason,
do not replace a m otor w ith one of the sam e nam eplate horsepow er but
w ith a low er service factor. Alw ays m ake certain that the replacem ent
m otor has a m axim um H P rating (rated H P x SF) equal to or higher than
that w hich it replaces. M ultiply the horsepow er by the service factor for
m axim um potential loading.
-26-
For easy reference, standard N EM A service factors for various horsepow er
m otors and m otor speeds are show n in this table.
The NEMA service factor for totally enclosed motors is 1.0.However, many manu-
facturers build TEFC with a 1.15 service factor.
Capacitors
Capacitors are used on all fractional H P induction m otors except shaded-
pole, split-phase and polyphase. Start capacitors are designed to stay in cir-
cuit a very short tim e (3-5 seconds), w hile run capacitors are perm anently
in circuit. Capacitors are rated by capacity and voltage. N ever use a capac-
itor w ith a voltage less than that recom m ended w ith the replacem ent
m otor. A higher voltage is acceptable.
Efficiency
A m otors efficiency is a m easurem ent of useful w ork produced by the
m otor versus the energy it consum es (heat and friction). An 84% efficient
m otor w ith a total w att draw of 400W produces 336 w atts of useful ener-
gy (400 x .84 = 336W ). The 64 w atts lost (400 - 336 = 64W ) becom es heat.
Thermal Protection (Overload)
A therm al protector, autom atic or m anual, m ounted in the end fram e or on
a w inding, is designed to prevent a m otor from getting too hot, causing
possible fire or dam age to the m otor. Protectors are generally current- and
tem perature-sensitive. Som e m otors have no inherent protector, but they
should have protection provided in the overall system s design for safety.
N ever bypass a protector because of nuisance tripping. This is generally an
indication of som e other problem , such as overloading or lack of proper
ventilation.
-27-
FOR DRIP PROOF MOTORS
Service Factor Synchronous Speed (RPM)
HP 3600 1800 1200 900
1
/
6
,
1
/
4,
1
/
3
1.35 1.35 1.35 1.35
1
/
2
1.25 1.25 1.25 1.25
3
/
4
1.25 1.25 1.15 1.15
1 1.25 1.15 1.15 1.15
1
1
/
2
up 1.15 1.15 1.15 1.15
W
I
R
E

G
A
G
E
N ever replace nor choose an autom atic-reset therm al overload protected
m otor for an application w here the driven load could cause personal injury
if the m otor should restart unexpectedly. O nly m anual-reset therm al over-
loads should be used in such applications.
Basic types of overload protectors include:
Automatic Reset: After the m otor cools, this line-interrupting pro-
tector autom atically restores pow er. It should not be used w here unex-
pected restarting w ould be hazardous.
Manual Reset: This line-interrupting protector has an external button
that m ust be pushed to restore pow er to the m otor. U se w here unex-
pected restarting w ould be hazardous, as on saw s, conveyors, com -
pressors and other m achinery.
Resistance Temperature Detectors: Precision-calibrated resistors
are m ounted in the m otor and are used in conjunction w ith an instru-
m ent supplied by the custom er to detect high tem peratures.
Individual Branch Circuit Wiring
All w iring and electrical connections should com ply w ith the N ational
Electrical Code (N EC) and w ith local codes and practices. U ndersized w ire
betw een the m otor and the pow er source w ill lim it the starting and load
carrying abilities of the m otor. The recom m ended copper w ire and trans-
form er sizes are show n in the follow ing charts.
Single Phase Motors - 230 Volts
-28-
Transformer Distance Motor to Transformer (Feet)
HP kVA 100 150 200 300 500
1.5 3 10 8 8 6 4
2 3 10 8 8 6 4
3 5 8 8 6 4 2
5 7.5 6 4 4 2 0
7.5 10 6 4 3 1 0
W
I
R
E

G
A
G
E
Three Phase Motors - 230 & 460 Volts
-29-
Transformer Distance Motor to Transformer (Feet)
HP Volts kVA 100 150 200 300 500
1.5 230 3 12 12 12 12 10
1.5 460 3 12 12 12 12 12
2 230 3 12 12 12 10 8
2 460 3 12 12 12 12 12
3 230 5 12 10 10 8 6
3 460 5 12 12 12 12 10
5 230 7.5 10 8 8 6 4
5 460 7.5 12 12 12 10 8
7.5 230 10 8 6 6 4 2
7.5 460 10 12 12 12 10 8
10 230 15 6 4 4 4 1
10 460 15 12 12 12 10 8
15 230 20 4 4 4 2 0
15 460 20 12 10 10 8 6
20 230 4 2 2 1 0
20 460 10 8 8 6 4
25 230 2 2 2 0 0
25 460 8 8 6 6 4
30 230 2 1 1 0 0
30 460 8 6 6 4 2
40 230 1 0 0 0 0
40 460 6 6 4 2 0
50 230 1 0 0 0 0
50 460 4 4 2 2 0
30 230 1 0 0 0 0
60 460 4 2 2 0 0
75 230 0 0 0 0 0
75 460 4 2 2 0 0
Consult
Local
Power
Company
-30-
Motor Starters
As their nam e im plies, m otor starters apply electric pow er to a m otor to
begin its operation. They also rem ove pow er to stop the m otor. Beyond
m erely sw itching pow er on and off, starters include overload protection,
as required by the N ational Electrical Code. The code also usually requires
a disconnect and short circuit protection on m otor branch circuits. Fused
disconnects and circuit breakers provide this and are often incorporated
into a m otor starter enclosure, resulting in a unit referred to as a com bi-
nation starter.
Full-voltage starters, also called across-the-line starters, apply full line volt-
age directly to the m otor, either through m anual or m agnetic contacts.
M agnetic starters are used on larger horsepow ers. Reversing starters, w hich
allow the sw itching of tw o leads to change m otor rotation, are also usual-
ly m agnetic.
Reduced-voltage starters, also called soft-starts, apply less than full voltage
during the starting sequence of a m otor. This reduces current and torque
surges, easing the strain on pow er supply system s and driven devices.
Resistors, transform ers or solid-state devices can achieve this voltage con-
trol. In addition, AC drives offer soft-start inherently. (See Chapter X for
com plete inform ation on AC drives.)
Both the N ational Electrical M anufacturers Association (N EM A) and the
International Electrotechnical Com m ission (IEC) rate starters to aid in
m atching them to the m otor and application.
-31-
Reading a LEESON Model Number
There is no independently established standard for setting up a m otors
m odel num ber, but the procedure is typically tied to descriptions of vari-
ous electrical and m echanical features. W hile other m anufacturers use
other designations, here is how LEESO N m odel num bers are configured.
EXAMPLE:
Position No. 1 2 3 4 5 6 7 8 9 10
Sample Model No. A B 4 C 17 D B 1 A (A-Z)
Position 1: U.L. Prefix
A Auto protector. U.L. recognized for locked rotor plus run,
also recognized construction (U.L. 1004)*.
M Manual protector. U.L. recognized for locked rotor plus run,
also recognized construction (U.L. 1004)*.
L Locked rotor protector (automatic). U.L. recognized for locked rotor
only, also recognized construction (U.L. 1004)*.
C Component recognition. (U.L. 1004) No protector.
U Auto protector. Not U.L. recognized.
P Manual protector. Not U.L. recognized.
T Thermostat, not U.L. recognized.
N No overload protection.
*This applies only to 48, S56, and 56 frame designs through 1 HP, Open & TENV.
Position 2: (Optional)
This position is not always used.
M Sub-Fractional HP Motors.
Z BISSC Approved.
Other Customer Code
Position 3: Frame
4 - 48 Frame 23 - 23 Frame 40 - 40 Frame
143 - 143T Frame 36 - 36 Frame 53 - 53 Frame
145 - 145T Frame 38 - 38 Frame 65 - 65 Frame
182 - 182T Frame 39 - 39 Frame
184 - 184T Frame
213 - 213T Frame
215 - 215T Frame
Position 4: Motor Type
C Cap. Start/Ind. Run TThree Phase
D Direct Current BBrushless DC
K Cap. Start/Cap. Run HHysteresis Sync.
P Permanent Split RReluctance Sync.
S Split Phase
Position 5: RPM
RPM-Single Speed RPM-Multi-Speed
34 - 3450 RPM 60 Hz 2 Pole 24 - 2 and 4 Poles
6 - 580 RPM 50 Hz 10 Pole
6 - 580 RPM 60 Hz 12 Pole
Odd frequencies other than 50 Hz show synchronous speed code.
DC and special motors may have one, two, or three digits indicating
motor speed rounded to the nearest hundred RPM.
Position 6: Enclosure
D Drip-Proof
E Explosion-Proof TENV
F Fan Cooled
N TENV
O Open
S Splashproof
W Weatherproof, Severe Duty, Chemical Duty,
WASHGUARD- TEFC
X Explosion-Proof TEFC
V Weatherproof, Severe Duty, Chemical Duty,
WASHGUARD- TENV
Position 7: Mounting
B Rigid base standard
C C face - no base - NEMA
D D flange - no base - NEMA
H 48 frame - 56 frame mounting/shaft rigid
J 48 frame - 56 frame mounting/shaft resilient
K Rigid mount with C flange
L Rigid mount with D flange
M Motor parts - rotor and stator
R Resilient base
S Shell motor
T Torpedo (face-less/base-less)
Z Special mounting
Position 8: Sequence Number
Number assigned as required when new designs
with new characteristics are needed.
Position 9: Modification Letter
Major modification letter. Used when revisions
made in existing model will affect service parts.
Position 10: (Optional)
A date code consisting of either A-Z,
and two digits 00-99.
-33- -32-
Capacitor Case*
Capacitor*
Frame
Stator
Starting
Switch*
(Rotating)
End Ring
Internal Fan
Shaft
Front Endshield
Cast Rotor
Starting
Switch*
(Stationary)
Fan Guard**
External
Fan**
Nameplate
Rear Endshield
Connection
Box
Base
Bearing
* SINGLE PHASE ONLY
** TEFC ONLY
Major Components of an Electric Motor
CHAPTER VI
Metric (IEC) Designations and Dimensions
The International Electrotechnical Com m ission (IEC) is a European-based
organization that publishes and prom otes w orldw ide m echanical and elec-
trical standards for m otors, am ong other things. In sim ple term s, it can be
said that IEC is the international counterpart to the N ational Electrical
M anufacturers Association (N EM A), w hich publishes the m otor standards
m ost com m only used throughout N orth Am erica.
D im ensionally, IEC standards are expressed in m etric units.
IEC / NEMA Dimensional Comparison
-34-
* Shaft dimensions of these IEC frames may vary between manufacturers.
** Horsepower listed is closest comparable rating with similar mounting
dimensions.In some instances, this results in a greater HP rating than
required.For example, 37 kW 4 pole converts to 50 HP but nearest HP
rating in the NEMA frame having comparable dimensions is 75 HP.
OBSERVE CAUTION if the drive train or driven load is likely to be dam-
aged by the greater HP.
Equivalent HP can be calculated by multiplying the kW rating by 1.341.
Multiply HP by .7457 to convert HP of kW.
To convert from millimeters to inches multiply by .03937.
To convert from inches to millimeters multiply by 25.
NOTES
-35-
Dimensions in Millimeters
KW/HP** Frame
Assignments
IEC D E F H U BA N-W
3 Phase TEFC
NEMA
2 Pole 4 Pole 6 Pole
56 56 45 35.5 5.8 9 36 20
NA
63 63 50 40 7 11 40 23 .25KW .18KW
NA 1/3HP 1/4HP
71 71 56 45 7 14 45 30 .55 .37
42 66.7 44.5 21.4 7.1 9.5 52.4 3/4 1/2
80 80 62.5 50 10 19 50 40 1.1 .75 .55KW
48 76.2 54 34.9 8.7 12.7 63.5 38.1 1-1/2 1 3/4HP
90S 90 70 50 10 24 56 50 1.5 1.1 .75
56 88.9 61.9 38.1 8.7 15.9 69.9 47.6 2 1-1/2 1
90L 90 70 62.5 10 24 56 50 2.2 1.5 1.1
56 88.9 69.8 50.8 8.7 22.2 57.2 57.2 3 2 1-1/2
100L 100 80 70 12 28 63 60 3 2.2 1.5
145T 88.9 69.8 63.5 8.7 22.2 57.2 57.2 4 3 2
112L 112 95 57 12 28 70 60 3.7 2.2 1.5
182T 114.3 95.2 57.2 10.7 28 70 69.9 5 3 2
112M 112 95 70 12 28 70 60 3.7 4 2.2
184T 114.3 95.2 68.2 10.7 28 70 69.9 5 5-4/5
132S 132 108 70 12 38 89 80 7.5 5.5 3
213T 133.4 108 69.8 10.7 34.9 89 85.7 10 7-1/2
132M 132 108 89 12 38 89 80 7.5 5.5
215T 133.4 108 88.8 10.7 34.9 89 85.7 10 7-1/2
160M* 160 127 105 15 42 108 110 15 11 7.5
254T 158.8 127 104.8 13.5 41.3 108 101.6 20 15 10
160L* 160 127 127 15 42 108 110 18.5 15 11
256T 158.8 127 127 13.5 41.3 108 101.5 25 20 15
180M* 180 139.5 120.5 15 48 121 110 22 18.5
284T 177.8 139.8 120.2 13.5 47.6 121 117.5 25
180L* 180 139.5 139.5 15 48 121 110 22 22 15
286T 177.8 139.8 139.8 13.5 47.6 121 117.5 30 30 20
200M* 180 159 133.5 19 55 133 110 30 30
324T 203.3 158.8 133.4 16.7 54 133 133.4 40 40
200L* 200 159 152.5 19 55 133 110 37 37 22
326T 203.2 158.8 152.4 16.7 54 133 133.4 50 50 30
225S* 225 178 143 19 60 149 140 37 30
364T 228.6 117.8 142.8 16.7 60.3 149 149.2 50/75 40
225M* 225 178 155.5 19 60 149 140 45 45 37
365 228.6 177.8 155.6 16.7 60.3 149 149.2 60/75 60/75 50
250M* 250 203 174.5 24 65 168 140 55 55
405T 254 203.2 174.6 20.6 73 168 182.2 75/100 75/100
280S* 280 228.5 184 24 75 190 140 45
444T 279.4 228.6 184.2 20.6 85.7 190 215.9 60/100
280M* 280 228.5 209.5 24 75 190 140 55
445T 279.4 228.6 209.6 20.6 85.7 190 215.9 75/125
See notes on facing page.
IEC Enclosure Protection Indexes
Like N EM A, IEC has designations indicating the protection provided by a
m otors enclosure. H ow ever, w here N EM A designations are in w ords, such
as O pen D rip Proof or Totally Enclosed Fan Cooled, IEC uses a tw o-digit
Index of Protection (IP) designation. The first digit indicates how w ell-pro-
tected the m otor is against the entry of solid objects; the second digit refers
to w ater entry.
By w ay of general com parison, an IP 23 m otor relates to O pen D rip Proof,
IP 44 to totally enclosed.
-36-
Protection Against Protection Against
Solid Objects Liquids
No. Definition No. Definition
0 No protection. 0 No protection.
1 Protected against solid objects 1 Protected against water
of over 50mm (e.g. accidental vertically dripping
hand contact). (condensation).
2 Protected against solid objects 2 Protected against water dripping
of over 12mm (e.g. finger). up to 15from the vertical.
3 Protected against solid objects 3 Protected against rain falling
of over 2.5mm (e.g. tools, wire). at up to 60from the vertical.
4 Protected against solid objects 4 Protected against water splashes
of over 1mm (e.g. thin wire). from all directions.
5 Protected against dust. 5 Protected against jets of water
from all directions.
6 Totally protected against dust. 6 Protected against jets of water
Does not involve rotating comparable to heavy seas.
machines.
7 Protected against the effects of
immersion to depths of between
0.15 and 1m.
8 Protected against the effects of
prolonged immersion at depth.
IEC Cooling, Insulation and Duty Cycle Indexes
IEC has additional designations indicating how a m otor is cooled (tw o-digit
IC codes). For m ost practical purposes, IC 01 relates to a N EM A open
design, IC 40 to Totally Enclosed N on-Ventilated (TEN V), IC 41 to Totally
Enclosed Fan Cooled (TEFC), and IC 48 to Totally Enclosed Air O ver
(TEAO ).
IEC w inding insulation classes parallel those of N EM A and in all but very
rare cases use the sam e letter designations.
D uty cycles are, how ever, different. W here N EM A com m only
designates either continuous, interm ittent, or special duty (typically
expressed in m inutes), IEC uses eight duty cycle designations.
S1 Continuous duty. The m otor w orks at a constant load for enough
tim e to reach tem perature equilibrium .
S2 Short-tim e duty. The m otor w orks at a constant load, but not long
enough to reach tem perature equilibrium , and the rest periods are
long enough for the m otor to reach am bient tem perature.
S3 Interm ittent periodic duty. Sequential, identical run and rest cycles
w ith constant load. Tem perature equilibrium is never reached.
Starting current has little effect on tem perature rise.
S4 Interm ittent periodic duty w ith starting. Sequential, identical start,
run and rest cycles w ith constant load. Tem perature equilibrium is
not reached, but starting current affects tem perature rise.
S5 Interm ittent periodic duty w ith electric braking. Sequential, iden-
tical cycles of starting, running at constant load, electric braking,
and rest. Tem perature equilibrium is not reached.
S6 Continuous operation w ith interm ittent load. Sequential, identical
cycles of running w ith constant load and running w ith no load. N o
rest periods.
S7 Continuous operation w ith electric braking. Sequential identical
cycles of starting, running at constant load and electric braking. N o
rest periods.
-37-
S8 Continuous operation w ith periodic changes in load and speed.
Sequential, identical duty cycles of start, run at constant load and
given speed, then run at other constant loads and speeds. N o rest
periods.
IEC Design Types
The electrical perform ance characteristics of IEC D esign N m otors in gen-
eral m irror those of N EM A D esign B the m ost com m on type of m otor for
industrial applications. By the sam e token, the characteristics of IEC
D esign H are nearly identical to those of N EM A D esign C. There is no spe-
cific IEC equivalent to N EM A D esign D . (See chart on Page 13 for char-
acteristics of N EM A design types.)
IEC Mounting Designations
-38-
Three common IEC mounting options are shown in this photo. From left, a B5
flange, B14 face and rigid B3 base.In this case, any of the options can be bolted
to a modularly designed round-body IEC 71 frame motor.
CHAPTER VII
Motor Maintenance
M otors, properly selected and installed, are capable of operating for m any
years w ith a reasonably sm all am ount of m aintenance.
Before servicing a m otor and m otor-operated equipm ent, disconnect the
pow er supply from m otors and accessories. U se safe w orking practices
during servicing of the equipm ent.
Clean m otor surfaces and ventilation openings periodically, preferably w ith
a vacuum cleaner. H eavy accum ulations of dust and lint w ill result in over-
heating and prem ature m otor failure.
Lubrication Procedure
M otors 10 H P and sm aller are usually lubricated at the factory to operate
for long periods under norm al service conditions w ithout re-lubrication.
Excessive or too frequent lubrication m ay actually dam age the m otor.
Follow instructions furnished w ith the m otor, usually on the nam eplate or
term inal box cover or on a separate instruction. If instructions are not
available, re-lubricate according to the chart on the next page. U se high-
quality ball bearing grease. G rease consistency should be suitable for the
m otors insulation class. For Class B, F or H , use a m edium consistency
polyurea grease such as Shell D olium R.
If the m otor is equipped w ith lubrication fitting, clean the fitting tip, and
apply grease gun. U se one to tw o full strokes on N EM A 215 fram e and
sm aller m otors. U se tw o to three strokes on N EM A 254 through N EM A 365
fram e. U se three to four strokes on N EM A 404 fram es and larger. For
m otors that have grease drain plugs, rem ove the plugs and operate the
m otor for 20 m inutes before replacing the plugs.
For m otors equipped w ith slotted head grease screw s, rem ove the screw
and insert a tw o-inch to three-inch long grease string into each hole on
m otors in N EM A 215 fram e and sm aller.
Insert a three-inch to five-inch length on larger m otors. For m otors having
grease drain plugs, rem ove the plug and operate the m otor for 20 m inutes
before replacing the plugs.
-39-
-40-
Relubrication Intervals Chart
For Motors Having Grease Fittings
Hours of Service HP Range Suggested
Per Year Relube Interval
5000 1/18 to 7
1
/
2
5 years
10 to 40 3 years
50 to 100 1 year
Continuous Normal to 7
1
/
2
2 years
Applications 10 to 40 1 year
50 to 100 9 months
Seasonal Service - All 1 year
Motor is idle for (beginning of
6 months or more season)
Continuous high 1/8 to 40 6 months
ambient, high 50 to 150 3 months
vibrations, or where
shaft end is hot
Caution: Keep grease clean. Lubricate motors at a standstill. Do not mix petroleum
grease and silicone grease in motor bearings.
CHAPTER VIII
Common Motor Types and
Typical Applications
Alternating Current Designs
Single Phase * Rigid Base Mounted * Capacitor Start * Totally Enclosed Fan
Cooled (TEFC) & Totally Enclosed Non-Vent (TENV)
G eneral purpose including com pressors, pum ps, fans, farm equipm ent,
conveyors, m aterial handling equipm ent and m achine tools.
Single Phase * Rigid Base Mounted * Capacitor Start * Open Drip
Proof (ODP)
G eneral purpose including com pressors, pum ps, conveyors, fans, m achine
tools and air conditioning units - usually inside or w here protected from
w eather, dust and contam inants.
Three Phase * Rigid Base Mounted * TEFC
G eneral purpose including pum ps, com pressors, fans, conveyors, m achine
tools and other applications w here three-phase pow er is available.
Three Phase * Rigid Base Mounted * ODP
G eneral purpose including pum ps, com pressors, m achine tools, convey-
ors, blow ers, fans and other applications requiring three-phase pow er, usu-
ally inside or w here protected from w eather, dust and contam inants.
Single Phase * NEMA C Face Less Base * Capacitor Start * TEFC & TENV
Pum ps, fans, conveyors, m achine tools and gear reducers.
Single Phase * NEMA C Face Less Base * Capacitor Start * ODP
Fans, blow ers, com pressors, tools and speed reducers.
Three Phase * NEMA C Face Less Base * TEFC & TENV
Fans, blow ers, com pressors, tools and speed reducers w here three-phase
pow er is suitable.
Three Phase * NEMA C Face Less Base * ODP
Fans, blow ers, com pressors, tools and speed reducers.
-41-
Washdown-Duty * Single & Three Phase * TENV & TEFC
Extended life in applications requiring regular hose-dow ns w ith cleaning
solutions, as in food processing and for applications in w et, high hum idi-
ty environm ents. Also available in direct current designs.
Explosion Proof * Single & Three Phase * TENV & TEFC
D esigned and listed for application in hazardous environm ents having cer-
tain explosive gases or m aterials present on equipm ent, such as blow ers,
pum ps, agitators or m ixers.
Chemical Service Motors * Rigid Base
Petrochem ical plants, foundries, pulp and paper plants, w aste m anagem ent
facilities, chem ical plants, tropical clim ates and other processing industry
applications requiring protection against corrosion caused by severe envi-
ronm ental operating conditions.
Brakemotors * Single & Three Phase
M achine tools, hoists, conveyors, door operators, speed reducers, valves,
etc., w hen stop and hold perform ance is required w hen pow er is rem oved
from the m otor by the use of a spring-set friction brake.
Resilient Mounted * Single & Three Phase * Moderate Starting
Torques
G eneral purpose applications w here quiet operation is preferred for fan
and blow er service.
Resilient Mounted * Single & Three Phase * Two Speed * Two Winding
* Variable Torque:
Belted or fan-on-shaft applications.
Rigid Mounted * Totally Enclosed Air Over (TEAO) * Single & Three
Phase
D ust-tight m otors for shaft-m ounted or belt-driven fans. The m otor
depends upon the fans airflow to cool itself.
HVAC Blower Motors * Three Phase * Automatic Reset Overload
Protector * Resilient Base * ODP
H eating, ventilating and air conditioning applications requiring m oderate
starting torque and therm al protection.
Condenser Fan Motors * Three Phase * Belly Band Mount * ODP
For operating vertical shaft-up on condenser fan, air-over applications,
such as rooftop air conditioning units.
-42-
Two Speed * Three Phase * Variable Torque
Fans, blow ers and centrifugal pum ps. Variable torque m otors have horse-
pow er ratings that vary as the square of the speed, w hile torque varies
directly w ith the speed.
Two Speed * Three Phase * Constant Torque
M ixers, com pressors, conveyors, printing presses, extractors, feeders and
laundry m achines. Constant torque m otors are capable of developing the
sam e torque for all speeds. Their horsepow er ratings vary directly w ith the
speed.
Two Speed * Three Phase * Constant Horsepower
M achine tools, such as drills, lathes, punch presses and m illing m achines.
Constant horsepow er m otors develop the sam e horsepow er at all operat-
ing speeds, and the torque varies inversely w ith the speed.
Jet Pump Motors * Single & Three Phase
Residential and industrial pum ps, plus sw im m ing pool pum ps. The pum p
im peller is m ounted to the m otor shaft.
JM Pump Motors * Single & Three Phase
Continuous duty service on close-coupled pum ps using N EM A JM m ount-
ing provisions. Com m only used for circulating and transferring fluids in
com m ercial and industrial w ater pum ps.
Compressor Duty * Single & Three Phase
Air com pressor, pum p-fan and blow er duty applications w hich require
high breakdow n torque and overload capacity m atching air com pressor
loading characteristics.
Woodworking Motors * Single Phase * TEFC
H igh torques for saw s, planers and sim ilar w oodw orking equipm ent.
Instant Reversing Motors * Resilient Mount * Single Phase * ODP
Specially designed m otors for use on instant-reversing parking gates,
doors, slide gates or other m oderate starting torque instant reversing appli-
cation; capable of frequent reversing service.
Pressure Washer Pump Motors * Rigid Mount & Rigid Mount with
NEMA C Face * Single Phase * ODP
H ot or cold pressure w ashers and steam cleaners.
-43-
IEC Metric Motors * Three Phase
For replacem ent on im ported m achined tools, textile m achinery and other
equipm ent having m etric dim ensioned m otors. Also available in direct cur-
rent designs.
Farm Duty * High Torque & Extra High Torque * Rigid Base Mount &
C Face Less Base
Severe agricultural equipm ent applications requiring high torques under
adverse operating conditions such as low tem peratures.
Agricultural Fan Duty * Resilient & Rigid Base Mount * Single & Three
Phase * TEAO
D ust-tight fan and blow er duty m otors for shaft-m ounted or belt-driven
fans. The m otor depends upon the fans air flow to cool itself.
Feed-Auger Drive Motors * Single Phase
D ust-tight auger m otors elim inate dam age caused w hen the m otor is over-
speeded by an obstructed auger. Special flange m ounts directly to the
auger gear reducer.
Hatchery/Incubator Fan Motor * Band Mounted * Single Phase *
TEAO
Replacem ent for use on poultry incubator fans. Includes extended through
bolts for attaching farm shroud.
Feather Picker Motor * Rigid Mount * Three Phase * TEFC
W ashdow n-duty m otor replaces the M EY N drive m otor of a processing
m achine that rem oves feathers from poultry.
Milk Transfer Pump Motor * Rigid Base * Single Phase * TENV
Replacem ent in dairy m ilk pum ps.
Grain Stirring Motors * Rigid Base * Single Phase * TEFC
D esigned to operate inside agricultural storage bins for stirring grain, corn,
and other agricultural products during the drying and storage process.
Irrigation Drive Motors * C Face Less Base * Three Phase * TEFC
For center pivot irrigation system s exposed to severe w eather environ-
m ents and operating conditions. D rives the tow er that propels sprinklers
in a circle around the w ell.
-44-
Direct Current Designs
High-Voltage, SCR-Rated Brush-Type * Permanent Magnet Field * C
Face With Removable Base * TEFC
G enerally used for conveyors, m achine tools, hoists or other applications
requiring sm ooth, accurate adjustable-speed capabilities through the use of
thyristor-based controls, often w ith dynam ic braking and reversing also
required. U sually direct-coupled to driven m achinery, w ith the m otor often
additionally supported by a base for m axim um rigidity. Such m otors are
also applicable w here extrem ely high starting torque, or high interm ittent-
duty running torques are needed, even if the application m ay not require
adjustable speed.
High-Voltage, SCR-Rated Brush-Type * Permanent Magnet Field *
Washdown-Duty Enhancements * C Face With Removable Base *
TENV
D esigned for extended life on food-processing m achines or other high-
hum idity environm ents w here adjustable speed is required.
Low-Voltage Brush-Type * Permanent Magnet Field * C Face With
Removable Base * TENV
For installations operating from battery or solar pow er, or generator-sup-
plied low -voltage D C. O ne key application is a pum p operating off a truck
battery. Like high-voltage counterparts, low -voltage designs provide linear
speed/torque characteristics over their entire speed range, as w ell as
dynam ic braking, easy reversing and high torque.
-45-
CHAPTER IX
Gear Reducers and Gearmotors
A gear reducer, also called a speed reducer or gear box, consists of a set
of gears, shafts and bearings that are factory-m ounted in an enclosed,
lubricated housing. G ear reducers are available in a broad range of sizes,
capacities and speed ratios. Their job is to convert the input provided by
a prim e m overinto output of low er RPM and correspondingly higher
torque. In industry, the prim e m over is m ost often an electric m otor,
though internal com bustion engines or hydraulic m otors m ay also be used.
There are m any types of gear reducers using various gear types to m eet
application requirem ents as diverse as low first cost, extended life, lim ited
envelope size, quietness, m axim um operating efficiency, and a host of
other factors. The discussion that follow s is intended only as a brief out-
line of the m ost com m on industrial gear reducer types, their characteristics
and uses.
Right-Angle Worm Gear Reducers
The m ost w idely used industrial gear reducer type is the right-angle w orm
reducer. W orm reducers offer long life, overload and shock load tolerance,
w ide application flexibility, sim plicity and relatively low cost.
In a w orm gear set, a threaded input shaft, called the w orm , m eshes w ith
a w orm gear that is m ounted to the output shaft. U sually, the w orm shaft
is steel and the w orm gear is bronze. This m aterial com bination has been
-46-
Cutaway view shows key compo-
nents of an industrial-duty worm
gear reducer. Note steel worm and
bronze worm gear. Seals on both
input and output shafts prevent
lubricant leakage.
show n to result in long life, sm ooth operation, and noise levels acceptable
for industrial environm ents.
The num ber of threads in the w orm shaft, related to the num ber of teeth
in the w orm gear, determ ine the speed reduction ratio. Single-reduction
w orm gear reducers are com m only available in ratios from approxim ately
5:1 through 60:1. A 5:1 ratio m eans that m otor input of 1750 RPM is con-
verted to 350 RPM output. A 60:1 ratio brings output RPM of the sam e
m otor to 29 RPM . G reater speed reductions can be achieved through dou-
ble-reduction m eaning tw o gear reducers coupled together.
The flip side of geared-dow nspeed is geared-uptorque. For the
m ajority of gear reducers in N orth Am erica, output torque is expressed in
inch-pounds or foot-pounds. O utside of N orth Am erica, the m etric unit of
torque, new ton-m eter, is m ost com m on. O utput speed and output torque
are the key application criteria for a gear reducer.
Parallel-Shaft Gear Reducers
Parallel-shaft units are typically built w ith a com bination of helical and spur
gears in sm aller sizes, and all helical gears in larger sizes. H elical gears,
w hich have teeth cut in helixes to m axim ize gear-to-gear contact, offer
higher efficiencies and quieter operation though at a correspondingly
higher cost than straight-tooth spur gears.
Single-reduction speed ratios are far m ore lim ited in parallel-shaft reducers
than in right-angle w orm reducers, but m ultiple reductions (or gear stages)
fit easily w ithin a single parallel-shaft reducer housing. As a result, the
availability of higher ratios is usually greater in parallel-shaft reducers and
gearm otors; ratios as high as 900:1 are com m on in sm all gearm otors.
-47-
Combination of spur and helical
gears can be seen in this cutaway
view of a sub-fractional horsepower
parallel-shaft gearbox. Note multiple
gear stages.
At left, a quill-style input worm gear reducer uses a hollow unput shaft and a
shallow mounting flange. At right, extended mounting flange accommodates a
solid-shaft to solid-shaft input with a flexible coupling joining the two shafts.
Gearmotors
An electric m otor com bined w ith a gear reducer creates a gearm otor. In
sub-fractional horsepow er sizes, integral gearm otors are the rule m ean-
ing the m otor and the reducer share a com m on shaft and cannot be sepa-
rated. For application flexibility and m aintenance reasons, a larger gear-
m otor is usually m ade up of an individual reducer and m otor coupled
together. This is m ost often accom plished by using a reducer having a
N EM A C input flange m ated to a N EM A C face m otor. LEESO N uses the
term G ear+M otor for its separable reducer and m otor packages.
-48-
Three-phase NEMA C face AC
motor combined with flanged
worm gear reducer results in a
workhorseindustrial gearmo-
tor. This straightforward
mounting approach is common
with motors ranging in sizes
from fractional through 20 HP
and larger.
Basic worm gear reducers can be easily modified with mounting accessories to
meet application needs. Four examples are shown.
N EM A C flange reducers are of tw o basic types based on how the m otor
and reducer shafts are coupled. The m ost straightforw ard type, and the
m ost com m only used in sm aller horsepow er applications, has a quill
input a hollow bore in the w orm into w hich the m otors shaft is insert-
ed. The other type, involving a reducer having a solid input shaft, requires
a shaft-to-shaft flexible coupling, as w ell as an extended N EM A C flange to
accom m odate the com bined length of the shafts.
Installation and Application Considerations
Mounting: In the m ajority of cases, gear reducers are base-m ounted.
Som etim es, m ounting bolts are driven directly into pre-threaded holes in
the reducer housing. O ther tim es, accessory bases are used. O utput
flange m ountings are also available.
-49-
Quill-input reducer with output
flange added
Vertical output shaft, extended-
height base, solid input shaft with
no mounting flange
Shaft-input reducer in vertical
position, deep NEMA C flange,
plus J stylebase
Quill-style input reducer with
added base;worm over
mounting position
Reducers having hollow output shafts are usually shaft-m ounted to the dri-
ven load. If no output flange or secondary base is used, a reaction arm
prevents the reducer housing from rotating.
D o not m ount reducers w ith the input shaft facing dow n. O ther than that,
they m ay generally be m ounted in any orientation. If the reducer is vent-
ed, be sure the vent plug is m oved to a location as close as possible to the
top of the unit, as show n in the exam ples below .
-50-
Hollow output shaft reducer with
reaction arm mounted. This model
also has quill input and shallow
NEMA C input flange.
Output Speed and Torque: These are the key criteria for m atching a gear
reducer to the application needs.
Center Distance: The basic m easurem ent or size reference for w orm gear
reducers. G enerally, the larger the center distance, the greater the reduc-
er capacity. Center distance is m easured from the centerline of the input
shaft to the centerline of the output shaft.
Horsepower: A reducers input horsepow er rating represents the m axi-
m um prim e m over size the reducer is designed to handle. O utput horse-
pow er, w hile usually listed by reducer m anufacturers, has little application
relevance. Speed and torque are the real considerations.
Overhung Load: This is a force applied at right angles to a shaft beyond
the shafts outerm ost bearing. Too m uch overhung load can cause bear-
ing or shaft failure. U nless otherw ise stated, a reducer m anufacturers
overhung load m axim um s are rated w ith no shaft attachm ents such as
sheaves or sprockets. The Am erican G ear M anufacturers Association pro-
vides factors, com m only called K factors, for various shaft attachm ents by
w hich the m anufacturers m axim um should be reduced. O verhung load
can be eased by locating a sheave or sprocket as close to the reducer bear-
ing as possible. In cases of extrem e overhung load, an additional outboard
bearing m ay be required.
The follow ing form ula can be used to calculate overhung load (O H L):
O H L (pounds) =
Torque (inch-pounds) x K (load factor constant of overhung load)
R (radius of pulley, sprocket or gear)
w here, K equals 1.00 for chain and sprocket, 1.25 for a gear, and 1.5 for a
pulley and v-belt.
Thrust Load: This is a force applied parallel to a shafts axis. M ixers, fans
and blow ers are am ong driven m achines that can induce thrust loads.
Exceeding m anufacturersm axim um s for thrust loading can cause prem a-
ture shaft and bearing failure.
Mechanical and Thermal Ratings: M echanical ratings refer to the m ax-
im um pow er a reducer can transm it based on the strength of its com po-
nents. M any industrial reducers, including LEESO N s, provide a 200% safe-
ty m argin over this rating for start-ups and m om entary overloads. Therm al
-51-
rating refers to the pow er a reducer can transm it continuously based on its
ability to dissipate the heat caused by operating friction.
In practice, the m ass of a cast iron reducer housing and its oil lubrication
system provide sufficient heat dissipation so that m echanical and therm al
ratings are essentially equal. Alum inum -housed or grease-lubricated
reducers have less heat dissipation m ass and therefore require considera-
tion of therm al rating.
Service Factor: Established by the Am erican G ear M anufacturers
Association (AG M A), gearing service factors are a m eans to adjust a reduc-
ers ratings relative to an applications load characteristics. Proper deter-
m ination of an applications service factor is critical to m axim um reducer
life and trouble-free service. U nless otherw ise designated, assum e a m an-
ufacturers ratings are based on an AG M A-defined service factor of 1.0,
m eaning continuous operation for 10 hours per day or less w ith no recur-
ring shock loads. If conditions differ from this, input horsepow er and
torque ratings m ust be divided by the service factor selected from one of
the tables below . In addition, AG M A has standardized service factor data
for a w ide variety of specific applications. Contact your m anufacturer for
this inform ation.
I nput Speed: G ear reducers are best driven at input speeds com m on in
industrial electric m otors, typically 1200, 1800 or 2500 RPM . This provides
sufficient splashfor the reducers lubrication system , but not so m uch as
to cause oil churning. For input speeds under 900 RPM or above 3000
RPM , consult the m anufacturer. Alternative lubricants m ay be suggested.
-52-
Graphic shows compact size of
an aluminum-housed worm
gear reducer compared with a
cast iron housed reducer of the
same center distance. Smaller
size and lighter weight can be
an application advantage in
many cases, but reduced mass
means that the reducers ther-
mal rating must be carefully
considered.
Special Environmental Considerations
G ear reducers are extrem ely rugged pieces of equipm ent w ith long life in
m ost types of pow er transm ission applications. M odern com ponents,
including seals and synthetic lubricants, are designed for sustained high-
tem perature operation. Extrem e heat, how ever, can be a problem . As a
rule of thum b, m axim um oil sum p tem perature for a speed reducer is
200F, or 100F above am bient tem perature, w hichever is low er.
Exceeding these guidelines can shorten the reducers life. Be sure to pro-
vide adequate air space around a reducer for heat dissipation. In som e
cases, it m ay be necessary to provide an external cooling fan. In a gear-
m otor application, the fan on a totally enclosed, fan cooled m otor can also
aid in cooling the reducer.
M oisture or high hum idity is another concern. A key instance of this is a
food processing environm ent requiring w ashdow ns. In such cases, con-
sider reducers w ith special epoxy coatings, external shaft seals, and stain-
less steel shaft extensions and hardw are. If a gearm otor is used, be sure
the m otor has sim ilar w ashdow n-duty features.
-53-
Duration of Service Uniform Moderate Heavy Extreme
(Hours per day) Load Shock Shock Shock
Occasional 1/2 Hour --* --* 1.0 1.25
Less than 3 Hours 1.0 1.0 1.25 1.50
3 - 10 Hours 1.0 1.25 1.50 1.75
Over 10 Hours 1.25 1.50 1.75 2.00
* Unspecified service factors should be 1.00 or as agreed upon by the user and manufacturer.
Hydraulic or Electric Single Cylinder Multi-Cylinder
Motor Engines Engines
1.00 1.50 1.25
1.25 1.75 1.50
1.50 2.00 1.75
1.75 2.25 2.00
2.00 2.50 2.25
Service Factor Conversions for Reducers
With Electric or Hydraulic Motor Input
Service Factor Conversions for Reducers
With Engine Input
Gear Reducer Maintenance
Industrial gear reducers require very little m aintenance, especially if they
have been factory-filled w ith quality, synthetic lubricant to a level sufficient
for all m ounting positions. In m ost cases, oil change w ill not be necessary
over the life of the reducer. It is recom m ended that oil be changed only
if repair or m aintenance needs otherw ise dictate gearbox disassem bly.
O il level should, how ever, be checked periodically and vent plugs inspect-
ed to ensure they are clean and operating.
O therw ise, general m aintenance procedures for any industrial equipm ent
apply. This includes m aking sure m ounting bolts and other attachm ents
are secure and that no other unusual conditions have occurred.
-54-
CHAPTER X
Adjustable Speed Drives
By definition, adjustable speed drives of any type provide a m eans of vari-
ably changing speed to better m atch operating requirem ents. Such drives
are available in m echanical, fluid and electrical types.
The m ost com m on m echanical versions use com binations of belts and
sheaves, or chains and sprockets, to adjust speed in set, selectable ratios
2:1, 4:1, 8:1 and so forth. Traction drives, a m ore sophisticated m echan-
ical control schem e, allow increm ental speed adjustm ents. H ere, output
speed is varied by changing the contact points betw een m etallic disks, or
betw een balls and cones.
Adjustable speed fluid drives provide sm ooth, stepless adjustable speed
control. There are three m ajor types. H ydrostatic drives use electric
m otors or internal com bustion engines as prim e m overs in com bination
w ith hydraulic pum ps, w hich in turn drive hydraulic m otors. H ydrokinetic
and hydroviscous drives directly couple input and output shafts.
H ydrokintetic versions adjust speed by varying the am ount of fluid in a
vortex that serves as the input-to-output coupler. H ydroviscous drives,
also called oil shear drives, adjust speed by controlling oil-film thickness,
and therefore slippage, betw een rotating m etallic disks.
An eddy current drive, w hile technically an electrical drive, nevertheless
functions m uch like a hydrokinetic or hydroviscous fluid drive in that it
serves as a coupler betw een a prim e m over and driven load. In an eddy
current drive, the coupling consists of a prim ary m agnetic field and sec-
ondary fields created by induced eddy currents. The am ount of m agnetic
slippage allow ed am ong the fields controls the driving speed.
In m ost industrial applications, m echanical, fluid or eddy current drives are
paired w ith constant-speed electric m otors. O n the other hand, solid state
electrical drives (also term ed electronic drives), create adjustable speed
m otors, allow ing speeds from zero RPM to beyond the m otors base speed.
Controlling the speed of the m otor has several benefits, including
increased energy efficiency by elim inating energy losses in m echanical
speed changing devices. In addition, by reducing, or often elim inating, the
need for w ear-prone m echanical com ponents, electrical drives foster
increased overall system reliability, as w ell as low er m aintenance costs.
For these and other reasons, electrical drives are the fastest grow ing type
of adjustable speed drive.
-55-
There are tw o basic drive types related to the type of m otor controlled
D C and AC. A D C direct current drive controls the speed of a D C m otor
by varying the arm ature voltage (and som etim es also the field voltage). An
alternating current drive controls the speed of an AC m otor by varying the
frequency and voltage supplied to the m otor.
DC Drives
D irect current drives are easy to apply and technologically straightforw ard.
They w ork by rectifying AC voltage from the pow er line to D C voltage,
then feeding adjustable voltage to a D C m otor. W ith perm anent m agnet
D C m otors, only the arm ature voltage is controlled. The m ore voltage sup-
plied, the faster the arm ature turns. W ith w ound-field m otors, voltage
m ust be supplied to both the arm ature and the field. In industry, the fol-
low ing three types of D C drives are m ost com m on:
DC SCR Drives: These are nam ed for the silicon controlled rectifiers (also
called thyristors) used to convert A C to controlled voltage D C.
Inexpensive and easy to use, these drives com e in a variety of enclosures,
and in unidirectional or reversing styles.
Regenerative SCR Drives: Also called four quadrant drives, these allow
the D C m otor to provide both m otoring and braking torque. Pow er com -
ing back from the m otor during braking is regenerated back to the pow er
line and not lost.
Pulse Width Modulated DC Drives: Abbreviated PW M and also called,
generically, transistorized D C drives, these provide sm oother speed control
w ith higher efficiency and less m otor heating. U nlike SCR drives, PW M
-56-
A general-purpose DC SCR dri-
ves family. From left, NEMA
4/12 totally enclosedversion,
chassis-mount,
NEMA 1 openenclosure.
types have three elem ents. The first converts AC to D C, the second filters
and regulates the fixed D C voltage, and the third controls average voltage
by creating a stream of variable w idth D C pulses. The filtering section and
higher level of control m odulation account for the PW M drives im proved
perform ance com pared w ith a com m on SCR drive.
AC Drives
AC drive operation begins in m uch the sam e fashion as a D C drive.
Alternating line voltage is first rectified to produce D C. But because an AC
m otor is used, this D C voltage m ust be changed back, or inverted, to an
adjustable-frequency alternating voltage. The drives inverter section
accom plishes this. In years past, this w as accom plished using SCRs.
H ow ever, m odern AC drives use a series of transistors to invert D C to
adjustable-frequency AC.
This synthesized alternating current is then fed to the AC m otor at the fre-
quency and voltage required to produce the desired m otor speed. For
exam ple, a 60 hz synthesized frequency, the sam e as standard line fre-
quency in the U nited States, produces 100% of rated m otor speed. A low er
frequency produces a low er speed, and a higher frequency a higher speed.
In this w ay, an AC drive can produce m otor speeds from , approxim ately,
15 to 200% of a m otors norm ally rated RPM by delivering frequencies of
9 hz to 120 hz, respectively.
Today, AC drives are becom ing the system s of choice in m any industries.
Their use of sim ple and rugged three-phase induction m otors m eans that
AC drive system s are the m ost reliable and least m aintenance prone of all.
Plus, m icroprocessor advancem ents have enabled the creation of so-called
vector drives, w hich provide greatly enhance response, operation dow n to
zero speed and positioning accuracy. Vector drives, especially w hen com -
-57-
With advances in power electronics,
even so-called microdrives can be
used with motors 40 HP or higher.
Full-featured unit shown includes
keypad programming and alphanu-
meric display.
bined w ith feedback devices such as tachom eters, encoders and resolvers
in a closed-loop system , are continuing to replace D C drives in dem and-
ing applications.
By far the m ost popular AC drive today is the pulse w idth m odulated type.
Though originally developed for sm aller-horsepow er applications, PW M is
now used in drives of hundreds or even thousands of horsepow er as
w ell as rem aining the staple technology in the vast m ajority of sm all inte-
gral and fractional horsepow er m icroand sub-m icroAC drives.
Pulse w idth m odulated refers to the inverters ability to vary the output
voltage to the m otor by altering the w idth and polarity of voltage pulses.
The voltage and frequency are sythesized using this stream of voltage puls-
es. This is accom plished through m icroprocessor com m ands to a series of
pow er sem iconductors that serve as on-off sw itches. Today, these sw itch-
es are usually IG BTs, or isolated gate bipolar transistors. A big advantage
to these devices is their fast sw itching speed resulting in higher pulse or
carrier frequency, w hich m inim izes m otor noise.
-58-
Encoders can be added to invert-
er-duty three-phase motors for
use in closed-loop vector drive
systems.
Sub-microdrives provide a
wide array of features in a very
small package.
One Piece Motor/Drive Combinations
Variously called intelligent m otors, sm art m otors or integrated m otors and
drives, these units com bine a three-phase electric m otor and a pulse w idth
m odulated inverter drive in a single package. Som e designs m ount the
drive com ponents in w hat looks like an oversize conduit box. O ther
designs integrate the drive into a special housing m ade to blend w ith the
m otor. A supplem entary cooling fan is also frequently used for the drive
electronics to counteract the rise in am bient tem perature caused by being
in close proxim ity to an operating m otor. Som e designs also encapsulate
the inverter boards to guard against dam age from vibration.
Size constraints lim it integrated drive and m otor packages to the sm aller
horsepow er ranges and require program m ing by rem ote keypad, either
hand-held or panel m ounted. M ajor advantages are com pactness and elim -
ination of additional w iring.
AC Drive Application Factors
As PW M AC drives have continued to increase in popularity, drives m anu-
facturers have spent considerable research and developm ent effort to build
in program m able acceleration and deceleration ram ps, a variety of speed
presets, diagnostic abilities, and other softw are features. O perator inter-
faces have also been im proved w ith som e drives incorporating plain-
Englishreadouts to aid set-up and operation. Plus, an array of input and
output connections, plug-in program m ing m odules, and off-line program -
m ing tools allow m ultiple drive set-ups to be installed and m aintained in a
fraction of the tim e spent previously. All these features have sim plified
drive applications. H ow ever, several basic points m ust be considered:
-59-
One-piece motor and drive com-
binations can be a pre-packaged
solution in some applications.
Unit shown incorporates drive
electronics and cooling system in
a special housing at the end of
the motor.
Torque: This is the m ost critical application factor. All torque require-
m ents m ust be assessed, including starting, running, accelerating and
decelerating and, if required, holding torque. These values w ill help
determ ine w hat current capacity the drive m ust have in order for the m otor
to provide the torque required. U sually, the m ain constraint is starting
torque, w hich relates to the drives current overload capacity. (M any drives
also provide a starting torque boost by increasing voltage at low er fre-
quencies.)
Perhaps the overriding question, how ever, is w hether the application is
variable torque or constant torque. M ost variable torque applications fall
into one of tw o categories air m oving or liquid m oving and involve
centrifugal pum ps and fans. The torque required in these applications
decreases as the m otor RPM decreases. Therefore, drives for variable
torque loads require little overload capacity. Constant torque applications,
including conveyors, positive displacem ent pum ps, extruders, m ixers or
other m achineryrequire the sam e torque regardless of operating speed,
plus extra torque to get started. H ere, high overload capacity is required.
Sm aller-horsepow er drives are often built to handle either application.
Typically, only a program m ing change is required to optim ize efficiency
(variable volts-to-hertz ratio for variable torque loads, constant volts-to-
hertz ratio for constant torque loads). Larger horsepow er drives are usu-
ally built specifically for either variable or constant torque applications.
Speed: As m entioned, AC drives provide an extrem ely w ide speed range.
In addition, they can provide m ultiple m eans to control this speed. M any
drives, for exam ple, include a w ide selection of preset speeds, w hich can
m ake set-up easier. Sim ilarly, a range of acceleration and deceleration
speed ram psare provided. Slip com pensation, w hich m aintains constant
speed w ith a changing load, is another feature that can be helpful. In addi-
tion, m any drives have program m able skip frequencies. Particularly w ith
fans or pum ps, there m ay be specific speeds at w hich vibration takes
place. By program m ing the drive to avoid these corresponding frequen-
cies, the vibration can be m inim ized. Another control function, com m on
w ith fans, is the ability for the drive to start into a load already in m otion
often called a rolling start or spinning start. If required, be sure your
drive allow s this or you w ill face overcurrent tripping.
Current: The current a m otor requires to provide needed torque (see pre-
vious discussion of torque) is the basis for sizing a drive. H orsepow er rat-
-60-
ings, w hile listed by drives m anufacturers as a guide to the m axim um
m otor size under m ost applications, are less precise. Especially for
dem anding constant torque applications, the appropriate drive m ay, in fact,
be oversizedrelative to the m otor. As a rule, general-purpose constant
torque drives have an overload current capacity of approxim ately 150% for
one m inute, based on nom inal output. If an application exceeds these lim -
its, a larger drive should be specified.
Power Supply: D rives tolerate line-voltage fluctuations of 10-15% before
tripping and are sensitive to pow er interruptions. Som e drives have
ride-thoughcapacity of only a second or tw o before a fault is triggered,
shutting dow n the drive. D rives are som etim es program m ed for m ultiple
autom atic restart attem pts. For safety, plant personnel m ust be aw are of
this. M anual restart m ay be preferred.
M ost drives require three-phase input. Sm aller drives m ay be available for
single-phase input. In either case, the m otor itself m ust be three-phase.
D rives, like any pow er conversion device, create certain pow er distur-
bances (called noiseor harm onic distortion) that are reflected back into
the pow er system to w hich they are connected. These disturbances rarely
affect the drive itself but can affect other electrically sensitive com ponents.
Control Complexity: Even sm all, low -cost AC drives are now being pro-
duced w ith im pressive features, including an array of program m able func-
tions and extensive input and output capability for integration w ith other
com ponents and control system s. Additional features m ay be offered as
options. Vector drives, as indicated previously, are one exam ple of
enhanced control capability for specialized applications.
In addition, nearly all drives provide som e m easure of fault logging and
diagnostic capability. Som e are extensive, and the easiest to use display
the inform ation in w ords and phrases rather than sim ply num erical codes.
Environmental Factors: The enem ies of electronic com ponents are w ell-
know n. H eat, m oisture, vibration and dirt are chief am ong them and obvi-
ously should be m itigated. D rives are rated for operation in specific m ax-
im um and m inim um am bient tem peratures. If the m axim um am bient is
exceeded, extra cooling m ust be provided, or the drive m ay have to be
oversized. H igh altitudes, w here thinner air lim its cooling effectiveness,
-61-
-62-
Examples of operating and diagnostic displays in a modern AC drive.
Drive Status
Speed Setpoint
Direction (Forward)
Speed Units
Drive Status
Percent Load
Direction (Forward)
Drive Status
Speed Setpoint
FAULT: OVERLOAD
RUN > 56. 00 HZ
RUN > 85%
call for special consideration. Am bient tem peratures too low can allow
condensation. In these cases, or w here hum idity is generally high, a space
heater m ay be needed.
D rive enclosures should be selected based on environm ent. N EM A 1
enclosures are ventilated and m ust be given room to breath. N EM A 4/12
enclosures, having no ventilation slots, are intended to keep dirt out and
are also used in w ashdow n areas. Larger heat sinks provide convection
cooling and m ust not be obstructed, nor allow ed to becom e covered w ith
dirt or dust. H igher-horsepow er drives are typically supplied w ithin
N EM A-rated enclosures. Sub-m icrodrives, in particular, often require a
custom er-supplied enclosure in order to m eet N EM A and N ational
Electrical Code standards. The enclosures of som e m icrodrives, espe-
cially those cased in plastic, m ay also not be N EM A-rated.
Motor Considerations With AC Drives
O ne draw back to pulse w idth m odulated drives is their tendency to pro-
duce voltage spikes, w hich in som e instances can dam age the insulation
system s used in electric m otors. This tendency is increased in applications
w ith long cable distances (m ore than 50 feet) betw een the m otor and drive
and w ith higher-voltage drives. In the w orst cases, the spikes can literally
poke a holeinto the insulation, particularly that used in the m otors
w indings. To guard against insulation dam age, som e m anufacturers now
offer inverter-duty m otors having special insulation system s that resist volt-
age spike dam age. For exam ple, LEESO N s system , used in all three-phase
m otors 1 H P and larger, is called IRIS (Inverter Rated Insulation System ).
Particularly w ith larger drives, it m ay be advisable to install line reactors
betw een the m otor and drive to choke off the voltage spikes. In addition,
som e increased m otor heating w ill inevitably occur because of the invert-
ers synthesizedAC w ave form . Insulation system s on industrial m otors
built in recent years, and especially inverter-duty m otors, can tolerate this
except in the m ost extrem e instances. A greater cooling concern involves
operating for an extended tim e at low m otor RPM , w hich reduces the flow
of cooling air and especially in constant torque applications w here the
m otor is heavily loaded even at low speeds. H ere, secondary cooling such
as a special blow er m ay be required.
-63-
Routine Maintenance of Electrical Drives
M ajor m aintenance, troubleshooting and repair of drives should be left to
a qualified technician, follow ing the drive m anufacturers recom m enda-
tions. H ow ever, routine m aintenance can help prevent problem s. H ere
are som e tips:
Periodically check the drive for loose connections or any other unusu-
al physical conditions such as corrosion.
Vacuum or brush heatsink areas regularly.
If the drives enclosure is N EM A 1, be sure vent slots are clear of dust
or debris.
If the drive is m ounted w ithin a secondary enclosure, again be sure
vent openings area clear and that any ventilation fans are operating
properly.
U nless it is otherw ise necessary for m ajor m aintenance or repair, the
drive enclosure should not be opened.
-64-
Constant-speed blower kits
can be added in the field,
providing additional cooling
to motors operated at low
RPM as part of an adjustable
speed drive system.
CHAPTER XI
Engineering Data
-65-
C C/F F C C/F F C C/F F
-45.4 -50 -58 15.5 60 140 76.5 170 338
-42.7 -45 -49 18.3 65 149 79.3 175 347
-40 -40 -40 21.1 70 158 82.1 180 356
-37.2 -35 -31 23.9 75 167 85 185 365
-34.4 -30 -22 26.6 80 176 87.6 190 374
-32.2 -25 -13 29.4 85 185 90.4 195 383
-29.4 -20 -4 32.2 90 194 93.2 200 392
-26.6 -15 -5 35 95 203 96 205 401
-23.8 -10 -14 37.8 100 212 98.8 210 410
-20.5 -5 -23 40.5 105 221 101.6 215 419
-17.8 -0 -32 43.4 110 230 104.4 220 428
-15 -5 -41 46.1 115 239 107.2 225 437
-12.2 -10 -50 48.9 120 248 110 230 446
-9.4 -15 -59 51.6 125 257 112.8 235 455
-6.7 -20 -68 54.4 130 266 115.6 240 464
-3.9 -25 -77 57.1 135 275 118.2 245 473
-1.1 -30 -86 60 140 284 120.9 250 482
-1.7 -35 -95 62.7 145 293 123.7 255 491
-4.4 -40 -104 65.5 150 302 126.5 260 500
-7.2 -45 -113 68.3 155 311 129.3 265 509
-10 -50 -122 71 160 320 132.2 270 518
-12.8 -55 -131 73.8 165 329 136 275 527
Temperature Conversion Table
Locate known temperature in C/F column.
Read converted temperature in C/F column.
F = (9/5 x C) + 32
C = 5/9 (F - 32)
-66-
I = amperes E = volts
Eff = efficiency kW - kilowatts
PF = power factor HP = horsepower
RPM = revolutions per minute kVA = kilovolt amperes
Use: Or:
To Find: SIngle Phase Three Phase
Amperes
Knowing HP
Amperes
Knowing kW
Amperes
Knowing kVA
Kilowatts
kVA
HP (output)
HP x 746
E x Eff x PF
HP x 746
1.73 x E x Eff x PF
kW x 1000
E x PF
kW x 1000
1.73 x E x PF
kVA x 1000
E
kVA x 1000
1.73 x E
I x E x PF
1000
1.73 x I x E x PF
1000
I x E
1000
1.73 x I x E
1000
I x E x Eff x PF
746
1.73 x I x E x Eff x PF
746
Electrical Characteristics
To Find: Use:
Torque in Inch-Pounds
Horsepower
RPM
Mechanical Characteristics Converting Torque Units
Inch-Pounds and Newton Meters
HP x 63,025
RPM
Torque (lb. in.) x RPM
5250
120 x Frequency
Number of Poles
Torque (lb. in.) = 8.85 x Nm
or
= 88.5 x daNm
Torque (Nm) = lb. in.
8.85
Torque (daNm) = lb. in.
88.5
-67-
Fraction Decimal Millimeter Fraction Decimal Millimeter MM Inch
1/64 - .015625 - 0.397 33/64 - .515625 - 13.097 1 - .039
1/32 - .03125 - 0.794 17/32 - .53125 - 13.494 2 - .0790
3/64 - .046875 - 1.191 35/64 - .546875 - 13.891 3 - .1181
1/16 - .0625 - 1.588 9/16 - .5625 - 14.288 4 - .1575
5/64 - .078125 - 1.984 37/64 - .578125 - 14.684 5 - .1969
3/32 - .09375 - 2.381 19/32 - .59375 - 15.081 6 - .2362
7/64 - .109375 - 2.778 39/64 - .609375 - 15.478 7 - .2756
1/8 - .125 - 3.175 5/8 - .625 - 15.875 8 - .3150
9/64 - .140625 - 3.572 41/64 - .640625 - 16.272 9 - .3543
5/32 - .15625 - 3.969 21/32 - .65625 - 16.669 10 - .3937
11/64 - .171875 - 4.366 43/64 - .671875 - 17.066 11 - .4331
3/16 - .1875 - 4.762 11/16 - .6875 - 17.462 12 - .4724
13/64 - .203125 - 5.129 45/64 - .703125 - 17.859 13 - .5119
7/32 - .21875 - 5.556 23/32 - .71875 - 18.256 14 - .5519
15/64 - .234375 - 5.953 47/64 - .734375 - 18.653 15 - .5906
1/4 - .25 - 6.350 3/4 - .75 - 19.050 16 - .6300
17/64 - .265625 - 6.747 49/64 - .765625 - 19.447 17 - .6693
9/32 - .28125 - 7.144 25/32 - .78125 - 19.844 18 - .7087
19/64 - .296875 - 7.541 51/64 - .796875 - 20.241 19 - .7480
5/16 - .3125 - 7.938 13/16 - .8125 - 20.638 20 - .7874
21/64 - .328125 - 8.334 53/64 - .828125 - 21.034 21 - .8268
11/32 - .34375 - 8.731 27/32 - .84375 - 21.431 22 - .8661
23/64 - .359375 - 9.128 55/64 - .859375 - 21.828 23 - .9055
3/8 - .375 - 9.525 7/8 - .875 - 22.225 24 - .9449
25/64 - .390625 - 9.921 57/64 - .890625 - 22.622 25 - .9843
13/32 - .40625 - 10.319 29/32 - .90625 - 23.019
27/64 - .421875 - 10.716 59/64 - .921875 - 23.416
7/16 - .4375 - 11.112 15/16 - .9375 - 23.812
29/64 - .453125 - 11.509 61/64 - .953125 - 24.209
15/32 - .46875 - 11.906 31/32 - .96875 - 24.606
31/64 - .484375 - 12.303 63/64 - .984375 - 25.003
1/2 - .5 - .12.700 1 - 1. - 25.400
To convert millimeters to inches, multiply by .03937
To convert inches to millimeters, multiply by 25.40
Fractional/Decimal/Millimeter Conversion
CHAPTER XII
Glossary
Actuator: A device that creates m echanical m otion by converting various
form s of energy to rotating or linear m echanical energy.
Adjustable Speed Drive: A m echanical, fluid or electrical device that
variably changes an input speed to an output speed m atching operating
requirem ents.
AGMA (American Gear Manufacturers Association): Standards
setting organization com posed of gear products m anufacturers and users.
AG M A standards help bring uniform ity to the design and application of
gear products.
Air-Over (AO): M otors for fan or blow er service that are cooled by the
air stream from the fan or blow er.
Alternating Current (AC): The standard pow er supply available from
electric utilities.
Ambient Temperature: The tem perature of the air w hich, w hen com ing
into contact w ith the heated parts of a m otor, carries off its heat. Am bient
tem perature is com m only know n as room tem perature.
Ampere (Amp): The standard unit of electric current. The current pro-
duced by a pressure of one volt in a circuit having a resistance of one ohm .
Armature:
The rotating part of a brush-type direct current m otor.
In an induction m otor, the squirrel cage rotor.
Axial Movement: O ften called endplay.The endw ise m ovem ent of
m otor or gear shafts. U sually expressed in thousandths of an inch.
Back Driving: D riving the output shaft of a gear reducer using it to
increase speed rather than reduce speed. W orm gear reducers are not suit-
able for service as speed increasers.
Backlash: Rotational m ovem ent of a gear reducers output shaft clock-
w ise and counter clockw ise, w hile holding the input shaft stationary.
U sually expressed in thousandths of an inch and m easure at a specific
radius at the output shaft.
-68-
Bearings:
Sleeve: Com m on in hom e-appliance m otors.
Ball: U sed w hen high shaft load capacity is required. Ball bearings
are usually used in industrial and agricultural m otors.
Roller: U se on output shafts of heavy-duty gear reducers and on
som e high-horsepow er m otors for m axim um overhung and
thrust load capacities.
Breakdown Torque: The m axim um torque a m otor can achieve w ith
rated voltage applied at rated frequency, w ithout a sudden drop in speed
or stalling.
Brush: Current-conducting m aterial in a D C m otor, usually graphite, or a
com bination of graphite and other m aterials. The brush rides on the com -
m utator of a m otor and form s an electrical connection betw een the arm a-
ture and the pow er source.
Canadian Standards Association (CSA): The agency that sets safety
standards for m otors and other electrical equipm ent used in Canada.
Capacitance: As the m easure of electrical storage potential of a capaci-
tor, the unit of capacitance is the farad, but typical values are expressed in
m icrofarads.
Capacitor: A device that stores electrical energy. U sed on single-phase
m otors, a capacitor can provide a starting boostor allow low er current
during operation.
Center Distance: A basic m easurem ent or size reference for w orm gear
reducers, m easured from the centerline of the w orm to the centerline of
the w orm w heel.
Centrifugal Starting Switch: A m echanism that disconnects the starting
circuit of a m otor w hen the rotor reaches approxim ately 75% of operating
speed.
Cogging: N on-uniform or erratic rotation of a direct current m otor. It usu-
ally occurs at low speeds and m ay be a function of the adjustable speed
control or of the m otor design.
Commutator: The part of a D C m otor arm ature that causes the electrical
current to be sw itched to various arm ature w indings. Properly sequenced
sw itching creates the m otor torque. The com m utator also provides the
m eans to transm it electrical current to the m oving arm ature through brush-
es that ride on the com m utator.
-69-
Counter Electromotive Force: Voltage that opposes line voltage caused
by induced m agnetic field in a m otor arm ature or rotor.
Current, AC: The pow er supply usually available from the electric utili-
ty com pany or alternators.
Current, DC: The pow er supply available from batteries, generators (not
alternators), or a rectified source used for special applications.
Duty Cycle: The relationship betw een the operating tim e and the resting
tim e of an electric m otor. M otor ratings according to duty are:
Continuous duty, the operation of loads for over one hour.
Intermittent duty, the operation during alternate periods of load and rest.
Interm ittent duty is usually expressed as 5 m inutes, 30 m inutes or one
hour.
Efficiency: A ratio of the input pow er com pared to the output, usually
expressed as a percentage.
Enclosure: The term used to describe the m otor housing. The m ost com -
m on industrial types are: O pen D rip Proof (O D P), Totally Enclosed Fan
Cooled (TEFC), Totally Enclosed N on-Ventilated (TEN V), Totally Enclosed
Air O ver (TEAO ). (See Chapter IV for additional inform ation).
Endshield: The part of a m otor that houses the bearing supporting the
rotor and acts as a protective guard to the internal parts of the m otor;
som etim es called endbell, endplate or end bracket.
Excitation: The act of creating m agnetic lines of force from a m otor
w inding by applying voltage.
Explosion-Proof Motors: These m otors m eet U nderw riters Laboratories
and Canadian Standards Association standards for use in hazardous (explo-
sive) locations, as indicated by the U L label affixed to the m otor. Locations
are considered hazardous because the atm osphere does or m ay contain
gas, vapor, or dust in explosive quantities.
Field: The stationary part of a D C m otor, com m only consisting of perm a-
nent m agnets. Som etim es used also to describe the stator of an AC m otor.
Flanged Reducer: U sually used to refer to a gear reducer having provi-
sions for close coupling of a m otor either via a hollow (quill) shaft or flex-
ible coupling. M ost often a N EM A C face m otor is used.
-70-
Foot-Pound: Energy required to raise a one-pound w eight against the
force of gravity the distance of one foot. A m easure of torque. Inch-pound
is also com m only used on sm aller m otors and gear reducers. An inch-
pound represents the energy needed to lift one pound one inch; an inch-
ounce represents the energy needed to lift one ounce one inch.
Form Factor: Indicates how m uch AC com ponent is present in the D C
output from a rectified AC supply. U nfiltered SCR (thyristor) drives have a
form factor (FF) of 1.40. Pure D C, as from a battery, has a form factor of
1.0. Filtered thyristor and pulse w idth m odulated drives often have a form
factor of 1.05.
Frame: Standardized m otor m ounting and shaft dim ensions as established
by N EM A or IEC.
Frequency: Alternating electric current frequency is an expression of how
often a com plete cycle occurs. Cycles per second describe how m any
com plete cycles occur in a given tim e increm ent. H ertz (hz) has been
adopted to describe cycles per second so that tim e as w ell as num ber of
cycles is specified. The standard pow er supply in N orth Am erica is 60 hz.
M ost of the rest of the w orld has 50 hz pow er.
Full Load Amperes (FLA): Line current (am perage) draw n by a m otor
w hen operating at rated load and voltage on m otor nam eplate. Im portant
for proper w ire size selection, and m otor starter or drive selection. Also
called full load current.
Full Load Torque: The torque a m otor produces at its rated horsepow er
and full-load speed.
Fuse: A piece of m etal, connected in the circuit to be protected, that
m elts and interrupts the circuit w hen excess current flow s.
Generator: Any m achine that converts m echanical energy into electrical
energy.
Grounded Circuit:
An electrical circuit coupled to earth ground to establish a reference
point.
A m alfunction caused by insulation breakdow n, allow ing current flow to
ground rather than through the intended circuit.
-71-
Hertz: Frequency, in cycles per second, of AC pow er; usually 60 hz in
N orth Am erica, 50 hz in the rest of the w orld. N am ed after H . R. H ertz,
the G erm an scientist w ho discovered electrical oscillations.
High Voltage Test: Application of a voltage greater than the w orking
voltage to test the adequacy of m otor insulation; often referred to as high
potential test or hi-pot.
Horsepower: A m easure of the rate of w ork. 33,000 pounds lifted one
foot in one m inute, or 550 pounds lifted one foot in one second. Exactly
746 w atts of electrical pow er equals one horsepow er. Torque and RPM
m ay be used in relating to the horsepow er of a m otor. For fractional horse-
pow er m otors, the follow ing form ula m ay be used.
H P = T (in.-oz) x 9.917 x N x 107
w here,
H P = horsepow er
T = Torque
N = revolutions per m inute
Hysteresis: The lagging of m agnetism in a m agnetic m etal, behind the
m agnetizing flux w hich produces it.
I EC (I nternational Electrotechnical Commission): The w orldw ide
organization that prom otes international unification of standards or norm s.
Its form al decisions on technical m atters express, as nearly as possible, an
international consensus.
I GBT: Stands for isolated gate bipolar transistor. The m ost com m on and
fastest-acting sem iconductor sw itch used in pulse w idth m odulated (PW M )
AC drives.
I mpedance: The total opposition in an electric circuit to the flow of an
alternating current. Expressed in ohm s.
I nduction Motor: The sim plest and m ost rugged electric m otor, it con-
sists of a w ound stator and a rotor assem bly. The AC induction m otor is
nam ed because the electric current flow ing in its secondary m em ber (the
rotor) is induced by the alternating current flow ing in its prim ary m em ber
(the stator). The pow er supply is connected only to the stator. The com -
bined electrom agnetic effects of the tw o currents produce the force to cre-
ate rotation.
-72-
I nsulation: In m otors, classified by m axim um allow able operating tem -
perature. N EM A classifications include: Class A = 105C, Class B = 130C,
Class F = 155C and Class H = 180C.
I nput Horsepower: The pow er applied to the input shaft of a gear
reducer. The input horsepow er rating of a reducer is the m axim um horse-
pow er the reducer can safely handle.
I ntegral Horsepower Motor: A m otor rated one horsepow er or larger
at 1800 RPM . By N EM A definitions, this is any m otor having a three digit
fram e num ber, for exam ple, 143T.
I nverter: An electronic device that changes direct current to alternating
current; in com m on usage, an AC drive.
Kilowatt: A unit of pow er equal to 1000 w atts and approxim ately equal
to 1.34 horsepow er.
Load: The w ork required of a m otor to drive attached equipm ent.
Expressed in horsepow er or torque at a certain m otor speed.
Locked Rotor Current: M easured current w ith the rotor locked and w ith
rated voltage and frequency applied to the m otor.
Locked Rotor Torque: M easured torque w ith the rotor locked and w ith
rated voltage and frequency applied to the m otor.
Magnetic Polarity: D istinguishes the location of north and south poles
of a m agnet. M agnetic lines of force em anate from the north pole of a m ag-
net and term inate at the south pole.
Mechanical Rating: The m axim um pow er or torque a gear reducer can
transm it. M any industrial reducers have a safety m argin equal to 200% or
m ore of their m echanical rating, allow ing m om entary overloads during
start-up or other transient overloads.
Motor Types: Classified by operating characteristics and/or type of pow er
required. The AC induction m otor is the m ost com m on. There are sever-
al kinds of AC (alternating current) induction m otors, including, for single-
phase operation: shaded pole, perm anent split capacitor (PSC), split
phase, capacitor start/induction run and capacitor start/capacitor run.
-73-
Polyphase or three-phase m otors are used in larger applications. D irect
current (D C) m otors are also com m on in industry as are gearm otors, brake-
m otors and other types. (See Chapter III for additional details).
Mounting: The m ost com m on m otor m ounts include: rigid base, resilient
base C face or D flange, and extended through bolts. (See Chapter IV for
additional details). G ear reducers are sim ilarly base-m ounted, flange-
m ounted, or shaft-m ounted.
National Electric Code (NEC): A safety code regarding the use of elec-
tricity. The N EC is sponsored by the N ational Fire Protection Institute. It is
also used by insurance inspectors and by m any governm ent bodies regu-
lating building codes.
NEMA (National Electrical Manufacturers Association): A non-prof-
it trade organization, supported by m anufacturers of electrical apparatus
and supplies in the U nited States. Its standards alleviate m isunderstanding
and help buyers select the proper products. N EM A standards for m otors
cover fram e sizes and dim ensions, horsepow er ratings, service factors, tem -
perature rises and various perform ance characteristics.
Open Circuit: A break in an electrical circuit that prevents norm al current
flow .
Output Horsepower: The am ount of horsepow er available at the output
shaft of a gear reducer. O utput horsepow er is alw ays less than the input
horsepow er due to the efficiency of the reducer.
Output Shaft: The shaft of a speed reducer assem bly that is connected
to the load. This m ay also be called the drive shaft or the slow speed shaft.
Overhung Load: A force applied at right angles to a shaft beyond the
shafts outerm ost bearing. This shaft-bending load m ust be supported by
the bearing.
Phase: The num ber of individual voltages applied to an AC m otor. A
single-phase m otor has one voltage in the shape of a sine w ave applied to
it. A three-phase m otor has three individual voltages applied to it. The
three phases are at 120 degrees w ith respect to each other so that peaks
of voltage occur at even tim e intervals to balance the pow er received and
delivered by the m otor throughout its 360 degrees of rotation.
Plugging: A m ethod of braking a m otor that involves applying partial or
full voltage in reverse to bring the m otor to zero speed.
-74-
Polarity: As applied to electric circuits, polarity indicates w hich term inal
is positive and w hich is negative. As applied to m agnets, it indicates w hich
pole is north and w hich pole is south.
Poles: M agnetic devices set up inside the m otor by the placem ent and
connection of the w indings. D ivide the num ber of poles into 7200 to deter-
m ine the m otors norm al speed. For exam ple, 7200 divided by 2 poles
equals 3600 RPM .
Power Factor: The ratio of apparent pow er(expressed in kVA) and
true or real pow er(expressed in kW ).
Pow er Factor =
Real Pow er
Apparent Pow er
Apparent pow er is calculated by a form ula involving the real pow er,that
w hich is supplied by the pow er system to actually turn the m otor, and
reactive pow er,w hich is used strictly to develop a m agnetic field w ithin
the m otor. Electric utilities prefer pow er factors as close to 100% as pos-
sible, and som etim es charge penalties for pow er factors below 90% .
Pow er factor is often im proved or correctedusing capacitors. Pow er fac-
tor does not necessarily relate to m otor efficiency, but is a com ponent of
total energy consum ption.
Prime Mover: In industry, the prim e m over is m ost often an electric
m otor. O ccasionally engines, hydraulic or air m otors are used. Special
application considerations are called for w hen other than an electric m otor
is the prim e m over.
Pull Out Torque: Also called breakdow n torque or m axim um torque, this
is the m axim um torque a m otor can deliver w ithout stalling.
Pull Up Torque: The m inim um torque delivered by a m otor betw een
zero and the rated RPM , equal to the m axim um load a m otor can acceler-
ate to rated RPM .
Pulse Width Modulation: Abbreviated PW M , the m ost com m on fre-
quency synthesizing system in AC drives; also used in som e D C drives for
voltage control.
Reactance: The opposition to a flow of current other than pure resis-
tance. Inductive reactance is the opposition to change of current in an
inductance (coil of w ire). Capacitive reactance is the opposition to change
of voltage in a capacitor.
-75-
Rectifier: A device or circuit for changing alternating current (AC) to
direct current (D C).
Regenerative Drive: A drive that allow s a m otor to provide both m otor-
ing and braking torque. M ost com m on w ith D C drives.
Relay: A device having tw o separate circuits, it is constructed so that a
sm all current in one of the circuits controls a large current in the other cir-
cuit. A m otor starting relay opens or closes the starting circuit under pre-
determ ined electrical conditions in the m ain circuit (run w inding).
Reluctance: The characteristics of a m agnetic field w hich resist the flow
of m agnetic lines of force through it.
Resistor: A device that resists the flow of electrical current for the pur-
pose of operation, protection or control. There are tw o types of resistors -
fixed and variable. A fixed resistor has a fixed value of ohm s w hile a vari-
able resistor is adjustable.
Rotation: The direction in w hich a shaft turns is either clockw ise (CW )
or counter clockw ise (CCW ). W hen specifying rotation, also state if view ed
from the shaft or opposite shaft end of m otor.
Rotor: The rotating com ponent of an induction AC m otor. It is typically
constructed of a lam inated, cylindrical iron core w ith slots for cast-alu-
m inum conductors. Short-circuiting end rings com plete the squirrel cage,
w hich rotates w hen the m oving m agnetic field induces a current in the
shorted conductors.
SCR Drive: N am ed after the silicon controlled rectifiers that are at the
heart of these controls, an SCR drive is the m ost com m on type of general-
purpose drive for direct current m otors.
Self-Locking: The inability of a gear reducer to be driven backw ards by
its load. M ost general purpose reducers are not self-locking.
Service Factor for Gearing: A m ethod of adjusting a reducers load car-
rying characteristics to reflect the applications load characteristics. AG M A
(Am erican G ear M anufacturers Association) has established standardized
service factor inform ation.
-76-
Service Factor for Motors: A m easure of the overload capacity built into
a m otor. A 1.15 SF m eans the m otor can deliver 15% m ore than the rated
horsepow er w ithout injurious overheating. A 1.0 SF m otor should not be
loaded beyond its rated horsepow er. Service factors w ill vary for different
horsepow er m otors and for different speeds.
Short Circuit: A fault or defect in a w inding causing part of the norm al
electrical circuit to be bypassed, frequently resulting in overheating of the
w inding and burnout.
Slip: The difference betw een RPM of the rotating m agnetic field and RPM
of the rotor in an induction m otor. Slip is expressed in percentage and m ay
be calculated by the follow ing form ula:
Speed Regulation: In adjustable speed drive system s, speed regulation
m easures the m otor and controls ability to m aintain a constant preset
speed despite changes in load from zero to 100% . It is expressed as a per-
centage of the drive system s rated full load speed.
Stator: The fixed part of an AC m otor, consisting of copper w indings
w ithin steel lam inations.
Temperature Rise: The am ount by w hich a m otor, operating under rated
conditions, is hotter than its surrounding am bient tem perature.
Temperature Tests: These determ ine the tem perature of certain parts of
a m otor, above the am bient tem perature, w hile operating under specific
environm ental conditions.
Thermal Protector: A device, sensitive to current and heat, w hich pro-
tects the m otor against overheating due to overload or failure to start. Basic
types include autom atic rest, m anual reset and resistance tem perature
detectors.
Thermal Rating: The pow er or torque a gear reducer can transm it con-
tinuously. This rating is based upon the reducers ability to dissipate the
heat caused by friction.
Thermostat: A protector, w hich is tem perature-sensing only, that is
m ounted on the stator w inding. Tw o leads from the device m ust be con-
nected to a control circuit, w hich initiates corrective action. The custom er
m ust specify if the therm ostats are to be norm ally closed or norm ally open.
-77-
Thermocouple: A pair of dissim ilar conductors joined to produce a ther-
m oelectric effect and used to accurately determ ine tem perature.
Therm ocouples are used in laboratory testing of m otors to determ ine the
internal tem perature of the m otor w inding.
Thrust Load: Force im posed on a shaft parallel to a shafts axis. Thrust
loads are often induced by the driven m achine. Be sure the thrust load rat-
ing of a gear reducer is sufficient so that its shafts and bearings can absorb
the load w ithout prem ature failure.
Torque: The turning effort or force applied to a shaft, usually expressed
in inch-pounds or inch-ounces for fractional and sub-fractional H P m otors.
Starting Torque: Force produced by a m otor as it begins to turn from
standstill and accelerate (som etim es called locked rotor torque).
Full-Load Torque: The force produced by a m otor running at rated full-
load speed at rated horsepow er.
Breakdown Torque: The m axim um torque a m otor w ill develop under
increasing load conditions w ithout an abrupt drop in speed and
pow er. Som etim es called pull-out torque.
Pull-Up Torque: The m inim um torque delivered by a m otor betw een
zero and the rated RPM , equal to the m axim um load a m otor can accel-
erate to rated RPM .
Transformer: U sed to isolate line voltage from a circuit or to change volt-
age and current to low er or higher values. Constructed of prim ary and sec-
ondary w indings around a com m on m agnetic core.
Underwriters Laboratories (UL): Independent U nited States testing
organization that sets safety standards for m otors and other electrical
equipm ent.
Vector Drive: An AC drive w ith enhanced processing capability that pro-
vides positioning accuracy and fast response to speed and torque changes.
O ften used w ith feedback devices in a closed-loop system .
Voltage: A unit of electrom otive force that, w hen applied to conductors,
w ill produce current in the conductors.
-78-
Watt: The am ount of pow er required to m aintain a current of 1 am pere
at a pressure of one volt w hen the tw o are in phase w ith each other. O ne
horsepow er is equal to 746 w atts.
Winding: Typically refers to the process of w rapping coils of copper w ire
around a core. In an AC induction m otor, the prim ary w inding is a stator
consisting of w ire coils inserted into slots w ithin steel lam inations. The
secondary w inding of an AC induction m otor is usually not a w inding at
all, but rather a cast rotor assem bly. In a perm anent m agnet D C m otor, the
w inding is the rotating arm ature.
-79-
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Basic Training: Motors, Gears & Drives

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MOTORS, GEARS & DRIVES

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