Kendall Connection Live Technologies DC Motor AC Motor PM DC Wound Series Shunt Compound Asynchronous Synchronous (Conventional) Single Phase Polyphase PMAC* Synchronous Reluctance

Kendall

Connection

Live

Mark Michalak

Keith Schultz

COMPANY CONFIDENTIALCopyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 2



Kendall

Connection

Live

Agenda

1. Permanent Magnet AC Motor (PMAC) Technology

2. Characteristics of PMAC motors

3. Drive considerations

4. Tools and Resources

5. SyMAX product line

6. Q&A

PMAC Technology Overview

VFD controls rotating stator field

Magnetic interaction between energized winding and permanent magnet rotor causes rotation

Every PMAC motor needs a DRIVE…Control opportunity!!

Video

../Symax - Marathon Motors.mp4

Motor Technologies

DC Motor AC Motor

PM DC Wound

SeriesShunt

Compound

Asynchronous

Synchronous (Conventional)

Single Phase Polyphase

PMAC*

Synchronous Reluctance

Line Start PM

Stepper

Universal Motor

Servo

Servo

Shaded poleSplit phase

PSCCapacitor startCapacitor run Wound rotor

Squirrel cage

Synchronous

Switched Reluctance

*Synonymous terms:PMAC = Permanent Magnet ACPMSM = Permanent Magnet Synchronous MotorBLAC = Brush Less ACECM or EC motor = Electronically Commutated Motor

Many names for the same basic motor technology

Back EMFReluctance TorqueInductanceSaliencyDemagnetizationMagnetic TorqueRipple TorqueCoggingRadial FluxAxial FluxIPMSPMCommutationElectromotive ForceMagnetomotive ForcePull-Out Torque

Generated voltage from rotation of a PM motorCreated when a structure tries to align itself to the lowest energy stateResistance to a change in current, causing current to lag voltageDifference between inductance values of the “D” and “Q” axesLoss of magnetic properties due to high temperature or currentTorque generated from magnetic interaction (magnet/field)Non-uniform angular velocity; “jerkiness” during rotationDetent felt when manually rotating a PM motor from alternating N & SMagnetic flux is perpendicular to shaft (a.k.a. “Sausage”)Magnetic flux is in line with the shaft (a.k.a. “Pancake”)Interior Permanent Magnet topology; magnets embedded in rotorSurface Permanent Magnet topology; magnets on O.D. of rotorProcess of energizing winding to facilitate interaction with magnetDriving force (“motive”)1 which produces voltageDriving force (“motive”)2 which produces magnetic fluxTorque required to pull motor out of synchronism with stator field

1 In PM circuits, the source is magnetic energy from the rotor2 In PM circuits, the source is electrical current from the stator

Terminology

PMAC vs. AC InductionDesign & Construction

AC Induction

• Die cast rotor

• Line or VFD power

• Low power density

• Narrow air gap

• Varying # poles within frame size

• Distributed winding

PMAC

• Permanent Magnet rotor

• VFD power only

• High power density

• Wider air gap

• Fixed pole count within frame size

• Distributed or concentrated winding

Fundamental difference is the ROTOR


VFD controls rotating stator field

Magnetic interaction between energized winding and permanent magnet rotor causes rotation

Every PMAC motor needs a DRIVE…Control opportunity!!


Two Winding Types• Distributed (induction)• Concentrated

Magnet Materials• Ferrite• High Energy (REM)

Neodymium Iron Boron (NdFeB)Samarium Cobalt (SmCo)

Stator Designs• Optimized # slots• Standard materials• Standard processes

Two Rotor Types• Surface mount (SPM)• Interior mount (IPM)• Optimized pole count

Stator winding type is usually same as Induction…ROTOR either SPM or IPM

Magnetic Saliency

d-axis inductance, Ld

N

SS

N magnet

steel

Low inductance path

q-axis inductance, Lq

N

SS

N magnet

steel

High inductance pathNo magnets

in the flux path.

Magnets

in the

flux path.

In a Salient PM Synchronous Machine, there is a difference between the rotor d-Axis (main Flux direction) and the rotor q-Axis (main torque producing direction) inductances.

IPM = Improved starting performance; Optimal magnet retention accommodates higher speeds

Agenda






6. Q&A

PMAC vs. AC InductionPerformance

AC Induction

• NEMA Premium (IE3) efficiency

• Steep efficiency curve

• Normal NEMA/IEC frame sizes

• Asynchronous (typical 3% slip)

PMAC

• Ultra Efficient (IE4+) efficiency

• Flat efficiency curve

• 2-3 frame size reduction

• Synchronous (0% slip)

• Inherent braking

• Excellent dynamic performance

• High system Power Factor

Premium Plus efficiency with enhanced form factor and outstanding speed/torque control

Efficiency: PMAC vs. NEMA Premium

0.70

0.75

0.80

0.85

0.90

0.95

0 200 400 600 800 1000 1200 1400 1600 1800 2000

Eff

icie

ncy

Speed (RPM)

Variable Speed Constant Torque Motor PerformanceEfficiency vs Speed

5 HP, 184T SyMAX PMAC vs NEMA Premium Induction

PM Motor Eff

Ind Motor Eff

91.7% (338 watts loss)


900


84.6% (679 watts loss) 23% improvement

43% improvement

20-30% more efficient at full load; 40-50% more efficient at reduced load

Calculator is located on the SyMAX Motors web site.

• Neodymium magnet cost stabilized – see below• Lower magnet wire content • Elimination of aluminum cost• Automation, driven by volume• PMAC ~25-30% more vs NEMA Premium Induction motor

0.0000

20.0000

40.0000

60.0000

80.0000

100.0000

120.0000

140.0000

Jul-

11

Oct

-11

Jan

-12

Ap

r-1

2

Jul-

12

Oct

-12

Jan

-13

Ap

r-1

3

Jul-

13

Oct

-13

Jan

-14

Ap

r-1

4

Jul-

14

Oct

-14

Jan

-15

Ap

r-1

5

Jul-

15

Oct

-15

Jan

-16

Ap

r-1

6

Jul-

16

Oct

-16

Jan

-17

Neodymium magnets

Cost Factors

Efficiency Gains through PMACCategory Typical Loss Factors Affecting Loss

Type and quantity of magnetic material

Chemical composition

Input frequency

Lamination thickness

Processing of lamination steel

Bearing selection

Fan design

Manufacturing processes

Grease type

Shaft seals

Stack length

Stator conductor size

Magnet wire material

Rotor conductor size

Material selection

Manufacturing processes

Design methods

"Catch all" for other losses not accounted for

Stray Load

15-25%

5-15%

25-40%

15-25%

10-20%

Core Loss

Friction & Windage

Stator I2R

Rotor I2R

Eliminated

Reduced

Reduced

Rotor conductor losses eliminated; no need to magnetize the rotor

Power Density

NEMA Premium AC Induction motor:10 HP, 1800 RPM, 215T frame

“Ultra Efficient” PMAC motor:10 HP, 1800 RPM, 184T frame

OR

Smaller footprint, lighter weight

“Ultra Efficient” PMAC motor:20 HP, 1800 RPM, 215T frame

Power Density

NEMA Premium AC Induction motor:10 HP, 1800 RPM, 215T frame

Motor’s torque density can eliminate costly belt and gearing systems

Dynamic Performance – Rotor Inertia

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00

4.50

48 56/140 180 210 250 280

Lb-F

t2

Motor Frame Size

Induction

PMAC

Average 37% Reduction

Low inertia rotor results in huge gain in dynamic performance

Agenda






6. Q&A

PM-Capable Drives

PowerFlex 753 – IPM onlyPowerFlex 755 – SPM or IPM

PowerFlex 525 – SPM or IPM

Performance-Matched to PowerFlex drives

General Drive Considerations

▪ Drives with PM Motor vector algorithms are recommended.

• Scalar Mode algorithms can work, with decreased efficiency.

• IPM control mode will provide the highest efficiency.

• SPM control mode will run the motor with good efficiency.

▪ Carrier Frequency must be greater than 10x the max motor operating frequency.

▪ Most drives need to be de-rated when using higher carrier frequencies.

▪ The drive’s amp rating should be no more than 2X motor FLA

▪ The nameplate values of Ld and Lq are measured open-circuit. Lq will decrease as current increases.

Operating in IPM mode results in best overall performance, open or closed loop

▪ Some drives have an “auto-tune” procedure that has the drive determine the parameter settings of the motor.

▪ Best practice: Use motor nameplate values

Commissioning

Auto-tune gets you in the ball park; nameplate parameters get you to home plate

Agenda






6. Q&A

https://www.regalbeloit.com/en/Brands/Marathon-Motors/Products/SyMAX

https://www.regalbeloit.com/Brands/Marathon-Motors/Tools-Resources

SyMAX® Motor

http://literature.rockwellautomation.com/idc/groups/literature/documents/um/520-um001_-en-e.pdfAppendix J has recommendations for PM Motor Setup.

http://literature.rockwellautomation.com/idc/groups/literature/documents/pm/750-pm001_-en-p.pdf

PowerFlex®

https://www.regalbeloit.com/en/Brands/Marathon-Motors/Products/SyMAX

https://www.regalbeloit.com/Brands/Marathon-Motors/Tools-Resources

http://literature.rockwellautomation.com/idc/groups/literature/documents/um/520-um001_-en-e.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/pm/750-pm001_-en-p.pdf

Efficiency: Payback Calculator

Calculator is located on the SyMAX Motors web site.






6. Q&A

p 29

Agenda

IP 43 Protection

Max Guard® Insulation

Natural NEMA Frame

Comprehensive Nameplate

Up to 5000 RPM

Totally Enclosed Non-Ventilated

With or without sensor feedback

48 to 215 frame mounting

Embedded rare earth magnet design

UL and cUL Component Recognition

Torque to 45 lb-ft

SyMAX® Commercial Motors

V-Ring “Forsheda” shaft seal (optional)

Natural NEMA Frame

IP 54 Protection(IP55 or 56 optional) Comprehensive Nameplate

Cast Iron Severe Duty Construction

Ultra Efficient™

IE4 levels,

Higher than NEMA Premium

Max Guard® Insulation

Terminal Block

(optional)

Cast Iron Bearing Caps (ea end)

Precision Balanced Rotor

Grounding Provisions on Frame/Foot

Epoxy interior & exterior paint

Encoder provisions

(optional)

TEFC – Standard

TENV or TEBC (optional)

SyMAX® Industrial Motors

p 32

HP kW IE3 IE4 IE5 SyMAX

0.5 0.37 N/A 81.5% 84.3% 84.0%

1 0.75 85.5% 85.5% 87.7% 87.5%

1.5 1.1 86.5% 87.5% 89.4% 89.2%

2 1.5 86.5% 88.5% 90.2% 90.2%

3 2.2 89.5% 91.0% 92.4% 91.7%

5 3.7 89.5% 91.0% 92.4% 93.9%

7.5 5.5 91.7% 92.4% 93.6% 92.4%

10 7.5 91.7% 92.4% 93.6% 94.5%

15 11 92.4% 93.6% 94.5% 94.0%

20 15 93.0% 94.1% 95.0% 94.5%

25 18.5 93.6% 94.5% 95.4% 94.5%

30 22 93.6% 94.5% 95.4% 95.4%

SyMAX vs IE3, IE4 and IE5

Efficiencies at 1800 RPM

MEETS OR EXCEEDS IE5

MEETS OR EXCEEDS IE4

Efficiency Ranges

Exceeds Federally mandated EISA NEMA Premium efficiencies!

Reliability and Service

MAX GUARD® Insulation System• CR200 Corona Resistant rated magnet wire

• Patented “low stress” winding configuration

• Long dependable motor life under the adverse thermal and dielectric stresses imposed by IGBT based PM drives

• Full Class H insulating materials

• Exceeds requirements of NEMA MG1, Part 31.4.4.1

• No drive-to-motor cable length restrictions!

Uncompromising Quality Standards

100

1000

10000

100000

1000000

70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250

Ho

urs

Total Motor Temp °C

Temp vs Life

Class B

Class F

Class H

Class H Insulation System with Class B temperature rise:32 x Normal Life

System Total Temp. Rise Life

B 130⁰ C B 20,000

F 20,000

B 103,000

H 20,000

F 103,000

B 650,000

H

155⁰ C

180⁰ C

F


Operating temperature impacts insulation life

Level Ambient Rise Total Temp

Standard 40 55 95

IEEE841 40 45 85

SyMAX 40 35 75

Bearing System

Type In./Sec.

Standard 0.16

Precision 0.08

SyMAX 0.04

Balance/Vibration


Unlimited Cable Length, Low Bearing Temps, Low Vibration – Increase in Service Time

SyMAX® Product Availability

Many ratings and configurations are available!

New, expanded stock motor offering

Stock Offering

THE WORLD LEADER in Variable Speed Technology!

PM-Capable Drives

PowerFlex-525

PowerFlex 753 and 755


▪ Drives with PM Motor vector algorithms are recommended (PF-755 uses Vector).

▪ Some drives with Scalar Mode algorithms can work, with decreased efficiency. (PF-525 uses Scalar)

▪ IPM control mode (that uses both Ld and Lq values) will provide the highest efficiency.

▪ SPM control mode will run the motor with reasonable efficiency.

▪ Carrier Frequency must be greater than 10x the max motor operating frequency.

▪ Most drives need to be de-rated when using higher carrier frequencies.

▪ The drive’s amp rating should be no more than 2X motor FLA

▪ In order to optimize efficiency of the motor, sometimes experimentation with drive settings is needed.

▪ “Tricking” the drive with incorrect values may or may not work well, depending on the drive and the load you’re trying to run. “Tricking” the drive should be avoided.

▪ Some drives have an “auto-tune” procedure that has the drive determine the parameter settings of the motor.

▪ These values are not always accurate and should be checked before running the motor.


VFD Drive and PMAC motor

Drive settings explained &Demonstrated

PF-525 with PMAC Motor Start-up Guide

1. If you use Software for the startup… Do Not use the Startup Wizard! It cannot select thePM mode setting while in that environment.

2. Set the following Parameters in the drive based on the PMAC motor’s Name plate data.Use the PMAC motor’s Base speed information not extended values (Values from themotor nameplate)Parameter 031 (nameplate volts) – 230 voltsParameter 032 (nameplate Hz) – 90hzParameter 034 (nameplate FLA) – 1.9 ampsParameter 035 (Motor Poles) – 6 polesParameter 036 (nameplate RPM) – 1800 rpmParameter 037 (nameplate Power) – .4KwParameter 039 (Torque Perf Mode) – 4 (PM – Permanent Magnet)Parameter 040 (Autotune) – 2 (Rotate Tune)Parameter 044 (Maximum Freq) – 90hz

3. Observe Parameter 497 [Flux Current Ref] verify it is about .6 x Motor NP FLA

4. Verify what type of PMAC motor you have and set Parameter 589 (PM Algor Sel)Algorithm 1 for IPM motors and Algorithm 2 for SPM motors.

5. Start the drive to perform the Auto-tune. This will take about 45 seconds to a minute to complete. The Motor will Rotate! And the end of the motor ramping to speed it should coast to stop.


6. Once the tune completes, you can set accel/decel times to the values that fit the application.

For motor stability do not set Accel or Decel below .5 seconds. Parameter 41 - Accel timeParameter 42 - Decel timeParameter 439 - S-curve

7. Observe operation during the Start and Stop functions and adjust Parameter 516 (PM Initial Sel) = 2 (Six Pulse). Six pulse seems to work well.

8. Observe operation during the Start and Stop functions and adjust Parameter 517 (PM DC Inject Cur) = 60% (default 30%). 60% seems to be a good starting point.

9. Observe operation at 100% speed as you change direction from forward to reverse you may need to change Parameter 518 (PM Align Time) = to a value less than the accel time (default 0.7s). Align time seems to work fine when it is set greater than .5 sec or is set at about 75% of Accel time.

10. Observe operation during the Start and Stop functions and adjust 519 (PM HFI NS Cur) 150% seems to work well. (default is 100%).


11. Check stability at the break frequency point (Parameter 533 Default is at 15hz) by decellingfrom max speed to the value in Parameter 533 (after PM auto tune has been done) if motor is stable skip the next step. If you notice instability or oscillations when the decel hits the break frequency go to next step.

12. Increase the break voltage percentage by changing Parameter 532 (Break Voltage) = 35% to 40% (default 25%) seems to work well.

13. Run motor throughout entire speed range to verify proper operation starting at frequency at or above 5hz.

14. Switch from forward to reverse several times and verify motor will transition through the ramp down to zero speed and then back up to speed in the new direction and still remain stable.

Special Parameters not mentioned above but you should be aware of:

Parameter 518 (align time) when starting or change from forward to reverse if motor goes unstable you may need to raise the accel time as well and this value. (tweak from .2 to 5 seconds). The align time is when the drive aligns its self to the rotor poles and commutates the motor. If you do not give it enough time for this to occur the motor may become unstable.


BEMF

Volts/1000rpm

Poles

Volts

Amps

Rated or Base RPM and Hz

R (resistance) Ld (in Henries) Lq (in mili Henries)

PMAC SyMax Motor Nameplate

R, Ld, and Lq values are phase only not Phase to Phase values

Documents

Kendall Connection Live Technologies DC Motor AC Motor PM DC Wound Series Shunt Compound Asynchronous Synchronous (Conventional) Single Phase Polyphase PMAC* Synchronous Reluctance