Technical Guide No.

105

AC Drive Motors
-- influence of drive on acoustical noise
Technical Guide:
The illustrations, charts and examples given in this article are intended solely to
illustrate the theory and application of drive technology. Because of the many
variables and requirements of applications, ABB Industrial Systems, Inc. cannot
assume responsibility or liability for actual use based on the content of this article.
Reproduction of any information in this article is prohibited without permission
from ABB Industrial Systems, Inc.

1996 ABB Industrial Systems, Inc. All Rights Reserved

ii
1.0 Introduction

Drive Contribution to Acoustical Noise

The output voltage waveform of an adjustable frequency drive is not a sine wave
but a series of square wave voltage pulses that result in a reasonable approxima-
tion of a sine wave current. Although there is an extensive history of successful
use of standard motors on this waveform, the possible effects of the waveform
should be carefully considered. One effect is the generation of acoustical noise in
addition to the noise ordinarily produced by an AC motor. This technical guide ex-
plains this phenomenon and gives recommendations on minimizing noise when
using ABB adjustable frequency drives.

Using This Guide

This guide has been designed to provide an understanding of the characteristics of
adjustable frequency drives as related to acoustical noise produced by the motors
used with them. The background discussion leads to recommendations for select-
ing and applying drives and motors to limit motor noise to an acceptable level.
Readers wanting to gain an understanding of AC drives and their influence on mo-
tor noise should start at Section 2.0 (page 2).
For recommendations on selecting, specifying and applying motors and drives,
please go straight to Section 4.0 (page 4).
The material is summarized in Section 5.0 (page 6).

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2.0 PWM Adjustable Frequency Drives
ABB adjustable frequency drives and most other AC drives that are available to-
day are Pulse Width Modulated (PWM) drives. Figure 1 illustrates the basic prin-
ciples of PWM drives. The rectifier converts input line power, which has a
nominally fixed voltage and frequency, to fixed voltage dc power. A filter then re-
duces the ripple voltage resulting from the rectification of the ac line. The inverter
changes the fixed voltage dc power to ac output power of an adjustable voltage
and frequency.
The output waveform consists of a series of rectangular voltage pulses with a fixed
height and adjustable width. Adjusting the overall pattern of positive vs. negative
pulses establishes the output frequency. The width of the individual pulses is var-
ied so that the effective voltage is regulated in proportion to the frequency. Proper
motor performance requires an essentially constant ratio of output voltage to out-
put frequency (volts per hertz or V/Hz).

Equipment Waveform Operation

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Figure 1 Principles of Operation for ABB Adjustable Frequency Drives

2
 The characteristics and effects of adjustable frequency waveforms are often ana-
lyzed using Fourier analysis. The basic principle of Fourier analysis is that any
periodic waveform is equivalent to the sum of an infinite series of variable ampli-
tude sine waves with frequencies which are integral multiples of the fundamental
frequency. These sine wave component parts are called harmonics.
One cycle of the output waveform at a given output voltage can be made from
many narrow pulses or fewer wider pulses. To generate a waveform containing
more pulses, the switching devices in the inverter must switch more often. The
rate at which the switches operate is called the switching frequency or carrier fre-
quency.

3.0 Acoustical Noise Produced By Motors

Regardless of power source, all AC motors produce a significant level of acousti-
cal noise during normal operation. The predominant sound is the sound produced
by the air that is forced through the motor or over its surface to cool the motor. In
addition, noise results from the small amount of vibration caused by the normal
electromagnetic and mechanical forces inside the motor.
The harmonic voltages that are present in the PWM waveform produce harmonic
currents in the stator of the motor. The magnetic fields produced by the harmonic
currents can cause vibrations in the mechanical structure of the motor stator. This
effect is more significant if the frequency of the harmonic currents corresponds to
the mechanical resonant frequency of some part of the motor. The most noticeable
effect of these vibrations is the resulting sound, which has a pitch equivalent to the
harmonic frequency.
The primary concern is the effect of noise on the comfort and safety of personnel.
If the sound level in a work area is near the upper limit for personnel safety, the
effect of adjustable frequency power on a motor might push the sound level over
the limit, but this is not a common problem. A more common problem is the dis-
turbance of a relatively quiet office area by a minor change in background noise
due to the sound produced by an adjustable frequency driven motor.
There may be some concern that the motor may be damaged by the vibrations pro-
ducing the sound. This should not be a concern. These vibrations occur at frequen-
cies where only a tiny vibration amplitude can produce a noticeable sound. There
have been a few reports of mechanical damage to winding insulation due to vibra-
tion of winding coils that were not well secured, but such problems have been very
rare.

3
4.0 Recommendations
If, when operating on 60 Hz sine wave power, the acoustical noise produced by
the motor is at least 3 dB below the maximum acceptable level, some combination
of the following measures will usually limit the noise to the acceptable level when
the motor is connected to an ABB adjustable frequency drive. These measures are
presented in order of usual preference.
Every motor reacts differently with respect to acoustical noise produced by a par-
ticular waveform. Two motors of the same design and rating from the same man-
ufacturer have been known to produce significantly different noise levels under
identical operating conditions due to subtle variations in motor manufacturing.
Therefore, it is not possible to accurately predict noise level for any given motor.

Use good quality, high efficiency motors

Motors that are well designed and constructed are generally less susceptible to the
effects of PWM waveforms. High efficiency motors are designed to operate at a
lower magnetic flux density, resulting in quieter operation.

Operate at reduced V/Hz

Reduced V/Hz operation can be employed in variable torque applications. These
are applications where the required torque is proportional to the square of speed
such as centrifugal pumps, fans or centrifugal compressors. By reducing the V/Hz
at lower speeds where less torque is required, the motor is allowed to run at a re-
duced magnetic flux density resulting in quieter operation.

Operate at the optimum switching frequency

There are three ways in which adjusting the switching frequency may reduce the
level of sound produced by the motor.
1. If the switching frequency or some harmonic of the switching frequency corre-
sponds to a mechanical resonant frequency of the motor, it may be possible to
reduce the noise level by raising or lowering the switching frequency to avoid
the resonant point.
2. As the frequency of sound increases above 2000 Hz, more sound power is re-
quired to produce a given level of loudness as sensed by the human ear or by a
sound level meter that is calibrated in dBA. Therefore, increasing the switching
frequency and thus the sound produced by the motor, may reduce the level of
sound perceived.
3. Because the motor is an inductive load, it represents a higher impedance for
harmonic voltages at higher frequencies. As a result, harmonic currents are re-
duced by raising the switching frequency. Reducing harmonic currents usually
also reduces the noise level.
Although increasing the switching frequency usually reduces the noise produced
by the motor, increasing the switching frequency also has a disadvantage. Every
time a switching device switches on or off, power is lost in the process. When the

4
switching frequency is increased, the switching devices are switched more often
causing an increase in power losses. Increased power losses mean increased oper-
ating temperature and reduced efficiency.
Caution: Before increasing the switching frequency above the facto-
ry setting, consult the instruction manual and check with ABB to in-
sure that, based on the ambient temperature and output currents
present, safe operating limits will not be exceeded.
To minimize operating frequency and maximize efficiency, it is best to set the
switching frequency at the lowest setting at which the sound level is acceptable.
This optimal switching frequency adjustment must be performed under actual ser-
vice conditions for each individual motor. Note: Some models may not have a
switching frequency adjustment.

Use The Critical Frequency Avoidance Adjustment

If the motor produces unacceptable noise only at a few specific operating speeds,
the Critical Frequency Avoidance adjustments can possibly be set to prevent the
drive from operating at specific speeds where problems are observed. In many ap-
plications, the drive can be locked out of a few narrow bands of the operating
speed range without significantly limiting the overall process performance.

5
5.0 Summary
This technical guide has described the influence of adjustable frequency operation
on the sound produced by AC motors and recommended measures to limit the
noise to an acceptable level. Following are some important points to remember:
n Regardless of power source, all AC motors produce a significant level of
acoustical noise during normal operation.
n The harmonic content of the PWM drive output waveform causes additional
noise at a pitch that is related to the harmonic frequency.
n In some installations, a motor may produce an objectionable level or frequency
of noise when operating on PWM drive power.
n It is not possible to accurately predict the total noise level for any given motor.
n It is usually possible to limit the noise to an acceptable level by applying one
or more of the following measures:
n Use a good quality motor of high efficiency design.
n Use reduced V/Hz operation in variable torque applications.
n Operate at the optimum switching frequency.
n Use the critical frequency avoidance adjustment.

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 3AUA 489002B3094 R0001Rev. 0
EFFECTIVE: February 21, 1997
SUPERCEDES: NONE
ST-312-105

ABB Industrial Systems Inc.

16250 W. Glendale Drive
New Berlin, WI 53151
USA
Telephone:(414) 785-3416
(800) 752-0696
Fax: (414) 785-0397
Printed In USA