Variation & Unbalance Part 1

Pump ED 101
Three Phase Voltage Variation & Unbalance – Part 1
Joe Evans, Ph.D http://www.PumpEd101.com
Three phase voltage variation and unbalance can have a significant effect upon
motor insulation life. Voltage variation is defined as the difference between the
motor nameplate voltage and the incoming source voltage. This assumes that the
all three phases are the same voltage. Variation can be either negative or positive.
Unlike variation, voltage unbalance refers to the differing voltages that can occur
in each of the three phases. This month’s article will review voltage variation.
Next month we will cover voltage unbalance.
Prior to the introduction of the T-Frame motor in 1964, low voltage motors were
designed to operate at 220 and 440 volts. Today, that standard is 230 and 460
volts and is referred to as the Utilization Voltage (ANSI C84.1). The reason that
these voltages were selected is that they reside in the middle of the service range
a utility is required to supply. They also allow for the voltage drop that can occur
due to the distance between the motor and the service entrance. The National
Electrical Manufacturers Association (NEMA) standards recommend that motors
should be designed to operate satisfactorily at a voltage variation of plus or minus
10%. For 230 volts that range is 207 to 253 volts and for 460 volts it is 414 to
506 volts. The word “satisfactorily” is important because parts of this range can
be less than optimal.
The graph seen in Figure 1 is

commonly used to show the
effect of voltage variation on
several motor performance
characteristics. It can be
used to show the general
effects but there will be
variations based upon a
particular motor design. The
intersection of the zero (0)
points on the x and y axes
represent the motor
nameplate voltage.
Effects of Low Voltage
The left side of the graph shows the effect of low voltage. A 10% reduction in
nameplate voltage reduces motor efficiency by about 2%. In most cases this will
convert that more costly, premium efficiency motor to the older, EPACT design.
That same voltage reduction will increase power factor by 5%. This is a good thing
but, there is a more efficient way to achieve improved power factor. Reduced
voltage has its largest effect on motor torque. As shown, a voltage reduction of
10% will result in a torque reduction of about 19%. This is not usually a concern
with variable torque machines such as centrifugal pumps and fans. It could,
however, be a problem with constant torque loads.
The most important characteristic is full load current at lower voltages. As shown
on the graph its increase is almost directly proportional to the reduction in voltage.
A voltage reduction of 10% will increase full load current by 10%. This is not
unexpected since the power in watts is proportional to the product of voltage and
amps. This is not a problem if the measured amperage remains below the
nameplate, full load amperage. If, however, the motor is loaded close to nameplate
horsepower, amperage will exceed the nameplate maximum. This is not necessarily
a problem if the 10% reduction is brief, as the motor’s service factor is designed
to handle intermittent voltage drops. If it is constant, the motor service factor is
eliminated and any additional voltage drop will increase the operating temperature.
The result will be a reduction in insulation life. When 230 volt motors are
operated on 208 volt power systems, the normal 15% service factor disappears and
additional voltage drops usually cannot be tolerated. Options include derating the
motor horsepower, upgrading to the next higher horsepower or using a motor
wound for 200 volts.
The final characteristic is starting amps. The opposite occurs when the motor
starts and starting amps are reduced with a reduction in voltage. This is the basis
for wye / delta and solid state, reduced voltage starters.
Effects of High Voltage
An increase in supply voltage above the motor nameplate rating has the opposite
effect of low voltage for most motor characteristics. There are, however, two
exceptions. The first is efficiency. It is also reduced at higher voltages but not
as much as it is at lower voltages. The second is Full Load Amps. Full load
amperage remains steady with small voltage increases but can increase rapidly
above 5%. For many motors, the full load amp curve is much steeper than the one
seen in Figure 1. Why do amps increase with a rise in voltage? Unfortunately, this
is not a simple power issue but has to do with the magnetic field produced in the
stator. At normal voltages, the motor windings create magnetic fields in the
stator laminations. As voltage increases, these fields can become saturated. Once
saturated, the field cannot increase in intensity so the motor draws more current
in hopes of overcoming the saturation. The onset of saturation is not dependent on
motor loading. It will occur in lightly loaded motors also. The higher current
caused by saturation increases the operating temperature and reduces insulation
life. Fortunately the newer, premium efficiency designs are somewhat more
tolerant of high voltage than older designs.
Torque undergoes a major increase with an increase in voltage. So do the starting

amps (inrush current) and we have to pay close attention to the number of starts
per hour when operating at a higher voltages. Remember that inrush current can
be five to seven times full load current. High voltage also causes a major reduction
in power factor which will increase circuit loading and possibly anger your utility.
The plus and minus 10% voltage tolerance recommended by NEMA should not be
used continuously. It is there to accommodate the normal ups and downs of plant
and utility supply voltage. If high voltage variation (plus or minus) is continuous it
is always best to correct it. Operating as close to nameplate voltage as possible
will maximize insulation life.
Joe Evans is responsible for customer and employee education at PumpTech Inc, a pump &
packaged systems manufacturer & distributor with branches throughout the Pacific Northwest.
He can be reached via his website www.PumpEd101.com. If there are topics that you would like
to see discussed in future columns, drop him an email.

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Pump ED 101

Three Phase Voltage Variation & Unbalance – Part 1

Joe Evans, Ph.D http://www.PumpEd101.com

The graph seen in Figure 1 is

Effects of High Voltage

Torque undergoes a major increase with an increase in voltage. So do the starting

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