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	<title>Bodine Electric Gearmotor Blog</title>
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		<title>Load Testing with Gearmotors &#8212; Know Your Current, Know Your Load</title>
		<link>http://gearmotorblog.wordpress.com/2012/01/23/load-testing-gearmotors/</link>
		<comments>http://gearmotorblog.wordpress.com/2012/01/23/load-testing-gearmotors/#comments</comments>
		<pubDate>Mon, 23 Jan 2012 16:25:35 +0000</pubDate>
		<dc:creator>Edmund Glueck</dc:creator>
				<category><![CDATA[Application Tips]]></category>
		<category><![CDATA[Engineering Talk]]></category>
		<category><![CDATA[Bodine Electric Company]]></category>
		<category><![CDATA[Brushless DC Gearmotor]]></category>
		<category><![CDATA[dc control]]></category>
		<category><![CDATA[Fractional Horsepower]]></category>
		<category><![CDATA[load torque]]></category>
		<category><![CDATA[motor torque]]></category>
		<category><![CDATA[output torque]]></category>
		<category><![CDATA[pmdc motors]]></category>

		<guid isPermaLink="false">http://gearmotorblog.wordpress.com/?p=758</guid>
		<description><![CDATA[Load Testing a Drive Application with a Brushless DC Gearmotor and Control    By Eman Elashye When designing a new piece of equipment that uses motors or gearmotors, design engineers must calculate how much motor torque will be needed to drive their application load. If the gearmotor or motor is undersized and too small, the product [...]<img alt="" border="0" src="http://stats.wordpress.com/b.gif?host=gearmotorblog.wordpress.com&amp;blog=8758402&amp;post=758&amp;subd=gearmotorblog&amp;ref=&amp;feed=1" width="1" height="1" />]]></description>
			<content:encoded><![CDATA[<p><strong>Load Testing a Drive Application with a Brushless DC Gearmotor and Control  </strong>  By Eman Elashye</p>
<p><a href="http://gearmotorblog.files.wordpress.com/2012/01/07470031_abl-3911.jpg"><img class="alignright  wp-image-768" title="Bodine type ABL-3911 brushless DC control" src="http://gearmotorblog.files.wordpress.com/2012/01/07470031_abl-3911.jpg?w=150&#038;h=204" alt="" width="150" height="204" /></a>When designing a new piece of equipment that uses motors or gearmotors, design engineers must calculate how much motor torque will be needed to drive their application load. If the gearmotor or motor is undersized and too small, the product will be underpowered and likely not meet all application requirements. If the gearmotor or motor delivers more power and torque than required, then it adds unnecessary cost, requires more space and can negatively affect the total weight of the equipment.</p>
<p>This tech note provides the design engineer with a procedure on how to check his or her calculations against real-world performance by load testing the application. A good way to determine how much the actual load is on a motor or gearmotor is to measure the amount of current it draws. Three-phase brushless DC (ECM) motors present a challenge to the engineer who wants to measure motor current. If the current is measured through the motor leads (i.e. the motor phases), the resulting current values will be useless and essentially make no sense.</p>
<p><a href="http://gearmotorblog.files.wordpress.com/2012/01/07470031_34b-5n.jpg"><img class="alignleft size-full wp-image-767" title="Bodine type 34B-5N brushless DC right-angle gearmotor" src="http://gearmotorblog.files.wordpress.com/2012/01/07470031_34b-5n.jpg?w=500" alt=""   /></a></p>
<p><strong>There is a simple way to accurately measure the current through the motor:</strong> measure the current through the motor fuse on the brushless DC control.*  The current measurement provides the DC bus current before it goes into the 3 phases of the motor, and therefore can be used to calculate the load (torque) at the motor/gearmotor shaft. This is possible because just as in PMDC motors or gearmotors, the measured current is directly proportional to the load (required torque). The measured DC bus current should be very close, if not equivalent, to the nameplate rated current, if the motor or gearmotor is loaded to the nameplate rated torque. Once the current measurement is obtained, the motor torque is calculated by multiplying the torque constant (Kt) for the motor/gearmotor by the current value measured. Gearmotor output torque can be calculated once the motor torque has been determined.</p>
<p><strong>Kt (oz-in./A) x I(A)=T (oz-in.)</strong></p>
<p><strong>Test Procedure:</strong></p>
<div id="attachment_766" class="wp-caption alignleft" style="width: 310px"><a href="http://gearmotorblog.files.wordpress.com/2012/01/07470031-3911-brushless-control_low.jpg"><img class="size-full wp-image-766" title="FIGURE 1. Motor fuse location on a Bodine type ABL-3911 control" src="http://gearmotorblog.files.wordpress.com/2012/01/07470031-3911-brushless-control_low.jpg?w=500" alt=""   /></a><p class="wp-caption-text">FIGURE 1. Motor fuse location on a Bodine type ABL-3911 control</p></div>
<div id="attachment_769" class="wp-caption alignleft" style="width: 232px"><a href="http://gearmotorblog.files.wordpress.com/2012/01/07470031-fig-1.jpg"><img class="size-full wp-image-769" title="FIGURE 2. Location of motor fuse and quick connect tabs M+ and MF3." src="http://gearmotorblog.files.wordpress.com/2012/01/07470031-fig-1.jpg?w=500" alt=""   /></a><p class="wp-caption-text">FIGURE 2. Location of motor fuse and quick connect tabs M+ and MF3.</p></div>
<div class="mceTemp"> </div>
<div class="mceTemp">This example uses a Bodine type ABL-3911 brushless DC control. This control accepts a 115VAC 50/60Hz input and delivers filtered 0-130VDC to a BLDC motor or gearmotor. Before performing any measurements, read the control instruction manual completely and carefully. Pay special attention to all warnings, cautions and safety rules. Failure to follow the instructions could produce safety hazards, which could injure personnel or damage the control, motor or other equipment. Dangerous voltages are present in the electronic control and motor, which could cause serious injury or death. Use extreme caution during handling, testing and adjusting. Only a properly trained technician or engineer should perform these measurements on a live board. Properly guard the electronic control and motor to prevent accidental contact by all persons. Finally, do not earth-ground any components of our control.</div>
<div class="mceTemp"> </div>
<div class="mceTemp">
<div id="attachment_765" class="wp-caption alignleft" style="width: 310px"><a href="http://gearmotorblog.files.wordpress.com/2012/01/07470031-fig-2.jpg"><img class="size-medium wp-image-765" title="FIGURE 3. Connect ammeter and external fuse holder to M+ and MF3." src="http://gearmotorblog.files.wordpress.com/2012/01/07470031-fig-2.jpg?w=300&#038;h=202" alt="" width="300" height="202" /></a><p class="wp-caption-text">FIGURE 3. Connect ammeter and external fuse holder to M+ and MF3.</p></div>
</div>
<div class="mceTemp"> </div>
<div class="mceTemp"><strong>As shown in Figure 3,</strong> measure the current by using the quick connect tabs on the board labeled M+ and MF3.</div>
<p>1. Remove the motor fuse from the on-board fuse holder.<br />
2. Connect floating wires to M+ and MF3.<br />
3. Place the motor fuse into an external fuse holder.<br />
4. Connect the fuse holder and the ammeter in series with M+ and MF3 as shown in figure 3.<br />
5. Measure the DC current using an ammeter.</p>
<p>* This test will only work with a non-PWM control, such as Bodine type ABL-3911 and ABL-3921. It will not work with a PWM control, such as Bodine&#8217;s low voltage models ABL-3905 or ABL-3907.</p>
<p><strong><em>Eman Elashye</em></strong><em> is an Application Support Specialist at Bodine Electric Company. She has a degree in Electrical Engineering and works in their customer support group in the Chicago area. </em></p>
<p>You can download the <strong>PDF</strong> version here: <strong><a title="Bodine Application Notes -- Load Testing with a Gearmotor" href="http://www.bodine-electric.com/Asp/PutStream.asp?Context=/ApplicationNotes/pdf/bodine_bldc_load_testing.pdf" target="_blank">Bodine Application Notes</a></strong></p>
<p><strong>p.s.: </strong>This method also works with our non-PWM DC motor speed controls and permanent magnet DC <a title="Bodine DC Products" href="http://www.bodine-electric.com/dcmotorsolutions" target="_blank">(PMDC) gearmotors and motors</a>.</p>
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		<media:content url="http://1.gravatar.com/avatar/140f4457d4103fb025cf09893b284c43?s=96&#38;d=identicon&#38;r=G" medium="image">
			<media:title type="html">Bodine Gearmotors</media:title>
		</media:content>

		<media:content url="http://gearmotorblog.files.wordpress.com/2012/01/07470031_abl-3911.jpg" medium="image">
			<media:title type="html">Bodine type ABL-3911 brushless DC control</media:title>
		</media:content>

		<media:content url="http://gearmotorblog.files.wordpress.com/2012/01/07470031_34b-5n.jpg" medium="image">
			<media:title type="html">Bodine type 34B-5N brushless DC right-angle gearmotor</media:title>
		</media:content>

		<media:content url="http://gearmotorblog.files.wordpress.com/2012/01/07470031-3911-brushless-control_low.jpg" medium="image">
			<media:title type="html">FIGURE 1. Motor fuse location on a Bodine type ABL-3911 control</media:title>
		</media:content>

		<media:content url="http://gearmotorblog.files.wordpress.com/2012/01/07470031-fig-1.jpg" medium="image">
			<media:title type="html">FIGURE 2. Location of motor fuse and quick connect tabs M+ and MF3.</media:title>
		</media:content>

		<media:content url="http://gearmotorblog.files.wordpress.com/2012/01/07470031-fig-2.jpg?w=300" medium="image">
			<media:title type="html">FIGURE 3. Connect ammeter and external fuse holder to M+ and MF3.</media:title>
		</media:content>
	</item>
		<item>
		<title>Considerations for Traction Motor Applications &#8212; AC, BLDC or PMDC Motors</title>
		<link>http://gearmotorblog.wordpress.com/2011/06/28/traction-motor-applications/</link>
		<comments>http://gearmotorblog.wordpress.com/2011/06/28/traction-motor-applications/#comments</comments>
		<pubDate>Tue, 28 Jun 2011 18:28:37 +0000</pubDate>
		<dc:creator>Edmund Glueck</dc:creator>
				<category><![CDATA[Application Tips]]></category>
		<category><![CDATA[Custom Solutions]]></category>
		<category><![CDATA[Engineering Talk]]></category>
		<category><![CDATA[AC Gearmotor]]></category>
		<category><![CDATA[Bodine Electric Company]]></category>
		<category><![CDATA[Brushless DC Gearmotor]]></category>
		<category><![CDATA[e-TORQ Direct Drive]]></category>
		<category><![CDATA[Fractional Horsepower]]></category>
		<category><![CDATA[INTEGRAmotor]]></category>
		<category><![CDATA[Inverter Duty]]></category>
		<category><![CDATA[Low-Voltage BLDC Motor]]></category>
		<category><![CDATA[Permanent Magnet DC Gearmotors]]></category>
		<category><![CDATA[Variable Speed AC Motors]]></category>
		<category><![CDATA[Variable Speed Gearmotors]]></category>

		<guid isPermaLink="false">http://gearmotorblog.wordpress.com/?p=683</guid>
		<description><![CDATA[A ”traction motor” is a motor or gearmotor used in a traction application. Golf carts, electric vehicles, locomotives, lift trucks, etc. Often “traction motors” also have mounting features, temperature sensors, wiring terminals that are useful in mounting the motors in a vehicle. They may also have a higher level of environmental protection against dust and [...]<img alt="" border="0" src="http://stats.wordpress.com/b.gif?host=gearmotorblog.wordpress.com&amp;blog=8758402&amp;post=683&amp;subd=gearmotorblog&amp;ref=&amp;feed=1" width="1" height="1" />]]></description>
			<content:encoded><![CDATA[<div class="mceTemp mceIEcenter" style="text-align:left;">
<div id="attachment_721" class="wp-caption alignleft" style="width: 310px"><a href="http://gearmotorblog.files.wordpress.com/2011/06/34b-hg_bodine-gearmotor_25a.jpg"><img class="size-medium wp-image-721" title="Bodine type 34B-HG Brushless DC Gearmotor - OEM Solutions" src="http://gearmotorblog.files.wordpress.com/2011/06/34b-hg_bodine-gearmotor_25a.jpg?w=300&#038;h=234" alt="Bodine type 34B-HG Brushless DC Gearmotor - OEM Solutions" width="300" height="234" /></a><p class="wp-caption-text">Bodine type 34B-HG Brushless DC Gearmotor</p></div>
<p>A ”<strong>traction motor</strong>” is a motor or gearmotor used in a traction application. Golf carts, electric vehicles, locomotives, lift trucks, etc. Often “traction motors” also have mounting features, temperature sensors, wiring terminals that are useful in mounting the motors in a vehicle. They may also have a higher level of environmental protection against dust and moisture. </p>
</div>
<div class="mceTemp mceIEcenter" style="text-align:left;">A “traction motor” can be brush DC (PMDC), brushless DC (electronically commutated), AC induction or whatever else seems to work. Many locomotives today are powered by AC induction motors. Smaller AC induction motors are used in traction applications such as fork lifts and mobility devices.</div>
<div class="mceTemp mceIEcenter" style="text-align:left;"> </div>
<div class="mceTemp mceIEcenter" style="text-align:left;">An AC induction motor will almost always be larger than a brushed DC (PMDC) motor of the same output power. Magnets are the key to making more power available in a smaller package. Brushless DC motors/gearmotors will also be smaller still – because a) the motors contain magnets and b) they have windings on the outside of the motor and can dissipate heat more easily than brush DC (PMDC) motor designs.</div>
<div class="mceTemp mceIEcenter" style="text-align:left;"> </div>
<div class="mceTemp mceIEcenter" style="text-align:left;">Most AC induction &#8220;traction motors&#8221; appear to be constructed with polyphase (3-phase) windings. This makes sense because 3-phase motors are more efficient than two phase or single phase AC motors. Efficiency (which ultimately relates to battery life) is usually a high concern to designers of products that use traction motors.</div>
<div class="mceTemp mceIEcenter" style="text-align:left;"> </div>
<div class="mceTemp mceIEcenter" style="text-align:left;"><strong>Bodine Electric Company can design and manufacture 24VAC, 3-phase induction motors, as well as a wide range of 12-24VDC permanent magnet DC (PMDC) or BLDC (ECM) motors or gearmotors. A low-voltage AC, 3-phase &#8220;traction motor&#8221; should be optimized for the application&#8217;s unique operating conditions, for example, motor laminations can be optimized for the larger wire size needed to handle the higher current.</strong></div>
<div class="mceTemp mceIEcenter" style="text-align:left;"> </div>
<div class="mceTemp mceIEcenter" style="text-align:left;">Copyright  <a title="Bodine Electric Company Home Page" href="http://www.bodine-electric.com/" target="_blank">Bodine Electric Company </a>©  06/2011.  All rights reserved.  Contributing author: MJG.</div>
<div class="mceTemp mceIEcenter" style="text-align:left;">
<dl class="wp-caption aligncenter">
<dt class="wp-caption-dt"><a href="http://gearmotorblog.files.wordpress.com/2011/06/bodine-traction-motor-applications_06-2011_75.jpg"><img class="size-full wp-image-707" title="Bodine Traction Motor Applications - Engineered Gearmotor Solutions" src="http://gearmotorblog.files.wordpress.com/2011/06/bodine-traction-motor-applications_06-2011_75.jpg?w=500&#038;h=140" alt="Variable speed AC, DC and BLDC Gearmotors" width="500" height="140" /></a></dt>
<dd class="wp-caption-dd">Bodine Traction Motor Applications &#8211; Engineered Gearmotor Solutions</dd>
</dl>
<p>&nbsp;</p>
<p>See also: <strong><a href="http://en.wikipedia.org/wiki/Traction_motor">http://en.wikipedia.org/wiki/Traction_motor</a></strong><strong>  &gt;&gt; &#8220;</strong><strong>Traction motor</strong> refers to an electric motor or gearmotor providing the primary rotational torque of a machine, usually for conversion into <a href="http://en.wikipedia.org/wiki/Linear_motion">linear motion</a> (<a title="Traction (engineering)" href="http://en.wikipedia.org/wiki/Traction_(engineering)">traction</a>).<strong>&#8220;</strong></p>
</div>
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			<media:title type="html">Bodine Gearmotors</media:title>
		</media:content>

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			<media:title type="html">Bodine type 34B-HG Brushless DC Gearmotor - OEM Solutions</media:title>
		</media:content>

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	</item>
		<item>
		<title>2011 Standard Products Catalog &#8220;S-17&#8243; from Bodine Electric Company</title>
		<link>http://gearmotorblog.wordpress.com/2011/06/22/new-catalog-from-bodine/</link>
		<comments>http://gearmotorblog.wordpress.com/2011/06/22/new-catalog-from-bodine/#comments</comments>
		<pubDate>Wed, 22 Jun 2011 14:37:15 +0000</pubDate>
		<dc:creator>Edmund Glueck</dc:creator>
				<category><![CDATA[Company News]]></category>
		<category><![CDATA[Distributor News]]></category>
		<category><![CDATA[Standard Products]]></category>
		<category><![CDATA[AC Gearmotor]]></category>
		<category><![CDATA[Bodine Electric Company]]></category>
		<category><![CDATA[Brushless DC Gearmotor]]></category>
		<category><![CDATA[Fractional Horsepower]]></category>
		<category><![CDATA[Permanent Magnet DC Gearmotors]]></category>
		<category><![CDATA[Variable Speed AC Motors]]></category>

		<guid isPermaLink="false">http://gearmotorblog.wordpress.com/?p=667</guid>
		<description><![CDATA[The all-new Catalog &#8220;S-17&#8243; is here! We completely redesigned our standard product catalog to make it even easier for you to find the right gearmotor or drive system for your application. Designed as a print companion to our web site, it features detailed specifications for over 1,200 AC induction, permanent magnet DC (PMDC) and brushless DC [...]<img alt="" border="0" src="http://stats.wordpress.com/b.gif?host=gearmotorblog.wordpress.com&amp;blog=8758402&amp;post=667&amp;subd=gearmotorblog&amp;ref=&amp;feed=1" width="1" height="1" />]]></description>
			<content:encoded><![CDATA[<div>
<div id="attachment_660" class="wp-caption alignleft" style="width: 241px"><a href="http://gearmotorblog.files.wordpress.com/2011/06/s-17_cover_04-08-2011_50.jpg"><img class="size-medium wp-image-660" title="2011 Bodine Standard Products Catalog S-17" src="http://gearmotorblog.files.wordpress.com/2011/06/s-17_cover_04-08-2011_50.jpg?w=231&#038;h=300" alt="2011 Bodine Standard Products Catalog S-17" width="231" height="300" /></a><p class="wp-caption-text">2011 Bodine Standard Products Catalog S-17</p></div>
<p><strong>The all-new Catalog &#8220;S-17&#8243; is here!</strong> We completely redesigned our standard product catalog to make it even easier for you to find the right gearmotor or drive system for your application. Designed as a print companion to our web site, it features detailed specifications for over 1,200 AC induction, permanent magnet DC (PMDC) and brushless DC (ECM) gearmotors, motors and motion controls.</p>
</div>
<div>Our new catalog lists over 100 new stock products, including our new line of <a href="http://www.bodine-electric.com/wx/">WX gearmotors</a>, our heavy-duty <a href="http://www.bodine-electric.com/ProductAnnouncements/48r_cg_and_42a_cg.asp">CG gearmotors</a>, and many new dual voltage (230/460VAC, 60Hz, 3-phase) <a href="http://www.bodine-electric.com/Asp/ProductGroup.asp?Context=6">Pacesetter Inverter Duty</a> products. We also added new 24VDC <a href="http://www.bodine-electric.com/Asp/ProductGroup.asp?Context=18">INTEGRAmotor</a> gearmotor models (right angle and parallel shaft) that are powered by the larger 34B/FV motor, and expanded our lineup of low-voltage permanent magnet <a href="http://www.bodine-electric.com/dcmotorsolutions/">DC products</a> for battery and solar powered applications.</div>
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<div id="attachment_662" class="wp-caption aligncenter" style="width: 230px"><a title="Download our New 2011 Stock Products Catalog &quot;S-17&quot;" href="http://www.bodine-electric.com/literature/s17/asp/AboutCatalog.asp" target="_blank"><img class="size-full wp-image-662 " title="Bodine Catalog S-17 Download Page - Click here!" src="http://gearmotorblog.files.wordpress.com/2011/06/s-17_catalog_bug_c_products-page.jpg?w=500" alt="Bodine Catalog S-17 Download Page - Click here!"   /></a><p class="wp-caption-text">Bodine Catalog S-17 Download Page</p></div>
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			<media:title type="html">Bodine Gearmotors</media:title>
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			<media:title type="html">2011 Bodine Standard Products Catalog S-17</media:title>
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		<title>High-Performance Type &#8220;48B&#8221; Brushless DC (ECM) Motors and Gearmotors</title>
		<link>http://gearmotorblog.wordpress.com/2011/02/15/brushless-dc-ecm-gearmotors/</link>
		<comments>http://gearmotorblog.wordpress.com/2011/02/15/brushless-dc-ecm-gearmotors/#comments</comments>
		<pubDate>Tue, 15 Feb 2011 19:44:24 +0000</pubDate>
		<dc:creator>Edmund Glueck</dc:creator>
				<category><![CDATA[Application Tips]]></category>
		<category><![CDATA[Custom Solutions]]></category>
		<category><![CDATA[Bodine Electric Company]]></category>
		<category><![CDATA[Brushless DC Gearmotor]]></category>
		<category><![CDATA[Fractional Horsepower]]></category>
		<category><![CDATA[Gearmotor]]></category>
		<category><![CDATA[Gearmotors]]></category>
		<category><![CDATA[INTEGRAmotor]]></category>
		<category><![CDATA[Low-Voltage BLDC Motor]]></category>
		<category><![CDATA[Solar Power]]></category>
		<category><![CDATA[Variable Speed Gearmotors]]></category>

		<guid isPermaLink="false">http://gearmotorblog.wordpress.com/?p=617</guid>
		<description><![CDATA[The new special-order 48B is twice as powerful as previous BLDC motors from Bodine. Delivering up to 1.5 HP (1100 Watts) output at 260VDC (3000RPM), it brings all the benefits of brushless DC technology to applications that in the past might have required higher-cost servo motors. The 48B is designed for applications such as large [...]<img alt="" border="0" src="http://stats.wordpress.com/b.gif?host=gearmotorblog.wordpress.com&amp;blog=8758402&amp;post=617&amp;subd=gearmotorblog&amp;ref=&amp;feed=1" width="1" height="1" />]]></description>
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<div id="attachment_624" class="wp-caption alignleft" style="width: 510px"><a href="http://gearmotorblog.files.wordpress.com/2011/02/bod_48b_landing_3.jpg"><img class="size-full wp-image-624" title="Bodine 48B Brushless DC (ECM) Motors and Gearmotors" src="http://gearmotorblog.files.wordpress.com/2011/02/bod_48b_landing_3.jpg?w=500&#038;h=353" alt="High-Performance Brushless DC (ECM) Motors and Gearmotors from Bodine" width="500" height="353" /></a><p class="wp-caption-text">Type 48B Brushless DC Motors and Gearmotors from Bodine</p></div>
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<div>The new special-order 48B is twice as powerful as previous BLDC motors from Bodine. Delivering <strong>up to 1.5 HP (1100 Watts) output at 260VDC (3000RPM),</strong> it brings all the benefits of brushless DC technology to applications that in the past might have required higher-cost servo motors. The 48B is designed for applications such as large area fans, solar power tracking systems, pumps, medical and industrial equipment.</div>
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<td><img src="http://www.bodine-electric.com/48b/Images/48b_1.jpg" border="0" alt="EBL Control" width="108" height="122" /></p>
<div style="text-align:center;"><strong>EBL Control</strong></div>
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<p style="text-align:center;"> </p>
<p>Because the 48B is a special-order product, virtually any aspect of the motor can be modified to fit your application requirements. Motor windings are available from 48VDC to 260VDC. Options such as accessory shafts, brakes, or encoders can also be supplied with any 48B gearmotor or motor. The 48B features a universal 56C mounting flange, but base mounting and alternative face mount configurations are available. The standard 48B configuration features a single connector for quick power and logic connections, but many other termination options can be accommodated. The 48B is rated IP-44, cURus/CE approvals are in process, and the product is also RoHS compliant.</p>
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<td width="130" valign="top"><img src="http://www.bodine-electric.com/48b/Images/48b_2.jpg" border="0" alt="48B-CG Gearmotor" width="128" height="96" /></p>
<div><strong>48B-CG Gearmotor</strong></div>
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<div><strong>The 48B can be supplied with parallel shaft or right-angle gearheads.</strong> When matched with the Type CG parallel shaft gearhead it can achieve up to 1,000 lb-in. (113 Nm) and a speed range of 3-125 rpm (with 2500 rpm winding). In combination with the Type 5H right-angle gearhead, the 48B provides 272 lb-in. (30 Nm) and a rated output speed range of 5-250 rpm (2500 rpm winding). Bodine Electric also manufactures a matching 115/230VAC input type EBL control that was designed for high-volume OEM applications. Bodine Electric’s EBL and ABL brushless DC controls are available to power the new 48B motors and gearmotors — providing a single-source motion control system.</div>
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<td><img src="http://www.bodine-electric.com/48b/Images/48b_3.jpg" border="0" alt="Type 22B, 34B, and 48B motors." width="140" height="91" /></p>
<div><strong>Type 22B, 34B, and 48B motors.</strong></div>
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</tbody>
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<p> </p>
<p>Not only do the specifications of the 48B compare favorably to much more costly servo motors, it requires less maintenance and will last longer than traditional brush-type permanent magnet DC motors. The brushless construction results in a cooler running, quieter motor that can accelerate and decelerate quickly. It can be used in place of brush-type motors in applications where high starting torque and linear speed-torque characteristics are critical. The 48B is also suitable for solar and battery powered applications in remote areas where no AC power is available.</p>
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<div>
<div><strong>More info on our new 48B-CG Brushless DC Gearmotor with Built-In Control (24VDC): </strong><a href="http://www.bodine-electric.com/customsolutions/">Custom Solutions</a></div>
<div>
<p style="text-align:center;"> </p>
<p style="text-align:center;">  Copyright  <a title="Bodine Electric Company Home Page" href="http://www.bodine-electric.com/" target="_blank">Bodine Electric Company </a>©  02/2011.  All rights reserved.</p>
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			<media:title type="html">Bodine Gearmotors</media:title>
		</media:content>

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			<media:title type="html">Bodine 48B Brushless DC (ECM) Motors and Gearmotors</media:title>
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		<media:content url="http://www.bodine-electric.com/48b/Images/48b_1.jpg" medium="image">
			<media:title type="html">EBL Control</media:title>
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		<media:content url="http://www.bodine-electric.com/48b/Images/48b_2.jpg" medium="image">
			<media:title type="html">48B-CG Gearmotor</media:title>
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		<media:content url="http://www.bodine-electric.com/48b/Images/48b_3.jpg" medium="image">
			<media:title type="html">Type 22B, 34B, and 48B motors.</media:title>
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		<title>What is a Sensorless Brushless DC Control? How does it work?</title>
		<link>http://gearmotorblog.wordpress.com/2010/11/30/sensorless-bldc-controls/</link>
		<comments>http://gearmotorblog.wordpress.com/2010/11/30/sensorless-bldc-controls/#comments</comments>
		<pubDate>Tue, 30 Nov 2010 18:44:54 +0000</pubDate>
		<dc:creator>Edmund Glueck</dc:creator>
				<category><![CDATA[Application Tips]]></category>
		<category><![CDATA[Engineering Talk]]></category>
		<category><![CDATA[BLDC]]></category>
		<category><![CDATA[Bodine Electric Company]]></category>
		<category><![CDATA[Brushless DC Gearmotor]]></category>
		<category><![CDATA[Fractional Horsepower]]></category>
		<category><![CDATA[Gearmotor]]></category>

		<guid isPermaLink="false">http://gearmotorblog.wordpress.com/?p=544</guid>
		<description><![CDATA[Back EMF with sensors aligned A sensorless brushless DC control consists of a power supply, a power stage, commutation logic, and startup logic. The key difference to an electronically commutated BLDC motor system is that the Hall sensor inputs are replaced by a system that measures generated voltage (BEMF = back EMF) and uses zero [...]<img alt="" border="0" src="http://stats.wordpress.com/b.gif?host=gearmotorblog.wordpress.com&amp;blog=8758402&amp;post=544&amp;subd=gearmotorblog&amp;ref=&amp;feed=1" width="1" height="1" />]]></description>
			<content:encoded><![CDATA[<div class="mceTemp" style="text-align:center;">
<dl class="wp-caption alignright">
<dt class="wp-caption-dt"><a href="http://gearmotorblog.files.wordpress.com/2010/11/sensorless_blog_back-emf-with-sensors-aligned_11-15-2010mbm.jpg"><img class="size-thumbnail wp-image-557" title="Sensorless Brushless DC Controls / Back EMF with sensors aligned" src="http://gearmotorblog.files.wordpress.com/2010/11/sensorless_blog_back-emf-with-sensors-aligned_11-15-2010mbm.jpg?w=150&#038;h=150" alt="Sensorless Brushless DC Controls / Back EMF with sensors aligned" width="150" height="150" /></a></dt>
<dd class="wp-caption-dd">Back EMF with sensors aligned</dd>
</dl>
</div>
<p>A sensorless brushless DC control consists of a power supply, a power stage, commutation logic, and startup logic. The key difference to an electronically commutated BLDC motor system is that the Hall sensor inputs are replaced by a system that measures generated voltage (BEMF = back EMF) and uses zero crossings to determine when to switch on (energize) the windings. </p>
<p>The screen shot on the right shows BEMF with hall sensor aligned to commutate a conventional BLDC (ECM) motor or gearmotor.</p>
<p><strong>How does the sensorless BLDC control work?</strong></p>
<p>The BLDC motor is started “open loop” by sequencing the power switches to start rotation. Usually this involves a fixed time interval based on inertia to accelerate the motor. Once the motor speed is high enough to “read” BEMF signals the commutation loop is closed allowing normal brushless motor operation.</p>
<p><strong>What are the limitations of a sensorless BLDC system?</strong></p>
<p>The initial BEMF detection is based on motor speed. Hence, the motor has to achieve a minimum speed for the BEMF sensing to work. In addition, BEMF sensing requires filtering to remove PWM noise. The filtering of the signals introduces delays in the measurements. All these limitations result in a speed range limitation that is normally between 5:1 and 10:1. Another issue that occurs with a sensorless BLDC motor and control system is that the motor shaft will likely move prior to starting up.</p>
<div class="mceTemp" style="text-align:center;">
<dl class="wp-caption alignnone">
<dt class="wp-caption-dt"><a href="http://gearmotorblog.files.wordpress.com/2010/11/sensorless_blog_back-emf_11-15-2010mbm-crop.jpg"><img class="size-medium wp-image-559" title="Sensorless BLDC Controls / Motor Back-EMF with drive PWM Noise " src="http://gearmotorblog.files.wordpress.com/2010/11/sensorless_blog_back-emf_11-15-2010mbm-crop.jpg?w=300&#038;h=266" alt="Sensorless BLDC Controls / Motor Back-EMF with drive PWM Noise" width="300" height="266" /></a></dt>
<dd class="wp-caption-dd">Motor Back-EMF with drive PWM Noise </dd>
</dl>
</div>
<p><strong>What are the benefits of a sensorless BLDC system?</strong></p>
<p>This simplified motor-control connection scheme might reduce the risk of mis-wiring the motor and control system.  In addition, one should see cost savings due to the elimination of hall sensors in the motor, and because less cables and connections are required. A sensorless BLDC motor will be a less complex assembly, the lack of an internal commutator might also allow for a slightly smaller motor size.</p>
<p><strong>What is Back EMF?</strong></p>
<p>Back EMF is the voltage produced across a winding of a motor due to the  winding turns being cut by a magnetic field while the motor is operating. This voltage is directly proportional to rotor velocity and is opposite in polarity to the applied voltage (sometimes also referred to as counter EMF)</p>
<div id="attachment_558" class="wp-caption aligncenter" style="width: 310px"><a href="http://gearmotorblog.files.wordpress.com/2010/11/sensorless_blog_back-emf-bemf-from-two-motor-phases_11-15-2010mbm.jpg"><img class="size-full wp-image-558" title="Sensorless BLDC Controls / Back EMF from two motor phases after filtering" src="http://gearmotorblog.files.wordpress.com/2010/11/sensorless_blog_back-emf-bemf-from-two-motor-phases_11-15-2010mbm.jpg?w=500" alt="Sensorless BLDC Controls / Back EMF from two motor phases after filtering"   /></a><p class="wp-caption-text"> Back EMF from two motor phases after filtering</p></div>
<p><em>Back EMF definition f</em><em>rom the <a title="The Bodine Small Motors Handbook" href="http://www.bodine-electric.com/TechTools/" target="_blank">Bodine Electric Small Motors</a></em><em><a title="The Bodine Small Motors Handbook" href="http://www.bodine-electric.com/TechTools/" target="_blank"> Handbook </a>- Glossary of Terms (p. G-2)</em></p>
<p class="MsoNormal" style="margin:0;"><strong><span style="font-family:Arial;" lang="EN"><span style="font-size:small;">Gearmotors with ﻿Built-In 24VDC Brushless Control:</span></span></strong></p>
<p class="MsoNormal" style="margin:0;"><span style="font-family:Arial;" lang="EN"><span style="font-size:small;">To minimize wiring and connection challenges with electronically commutated BLDC (ECM) motors and gearmotors, Bodine Electric offers a stock selection of <strong>INTEGRAmotors</strong> and gearmotors. Our INTEGRAmotors offer a cost competitive, all-in-one, easy to wire brushless DC drive solution for specialty machine builders and OEMs that don&#8217;t want to deal with high-cost and very complex stepper or servo systems. <strong>For more info, click here: <a title="INTEGRAmotor a Smart Choice..." href="http://www.bodine-electric.com/choice/" target="_blank">INTEGRAmotor, a smart choice</a>&#8230;</strong></span></span> <span style="font-family:Arial;" lang="EN"><span style="font-size:small;"> </span></span><span style="font-family:Arial;" lang="EN"><span style="font-size:small;">  </span></span><span style="font-family:Arial;" lang="EN"> </span></p>
<div id="attachment_589" class="wp-caption aligncenter" style="width: 510px"><a href="http://gearmotorblog.files.wordpress.com/2010/11/integra_group_black_cropped_25.jpg"><img class="size-full wp-image-589" title="Bodine INTEGRAmotor - BLDC (ECM) Motors and Gearmotors" src="http://gearmotorblog.files.wordpress.com/2010/11/integra_group_black_cropped_25.jpg?w=500&#038;h=327" alt="Bodine INTEGRAmotor - BLDC (ECM) Motors and Gearmotors" width="500" height="327" /></a><p class="wp-caption-text">Bodine INTEGRAmotor - BLDC (ECM) Motors and Gearmotors with Built-in Controls and Feedback</p></div>
<p class="MsoNormal" style="margin:0;"><span style="font-family:Arial;" lang="EN"><span style="font-size:small;">As always, we hope you find this information interesting. If you have comments or questions, please leave your comment here, or send an e-mail to: <a href="mailto:edmund.glueck@bodine-electric.com">edmund.glueck@bodine-electric.com</a>  </span></span></p>
<p class="MsoNormal" style="margin:0;"><span style="font-family:Arial;" lang="EN"><span style="font-size:small;"> </span></span></p>
<p class="MsoNormal" style="margin:0;"><span style="font-family:Arial;" lang="EN"><span style="font-size:small;">Regards, Edmund </span></span><span style="font-family:Arial;" lang="EN"><span style="font-size:small;"> </span></span><span style="font-family:Arial;" lang="EN"><span style="font-size:small;">[Manager, Marketing and Product Development/Standard Products] </span></span></p>
<p class="MsoNormal" style="margin:0;"><span style="font-family:Arial;" lang="EN"><span style="font-size:small;"> </span></span></p>
<p class="MsoNormal" style="text-align:center;margin:0;"><span style="font-family:Arial;" lang="EN"> </span><span style="font-family:Arial;font-size:10pt;" lang="EN">Copyright  <a title="Bodine Electric Company Home Page" href="http://www.bodine-electric.com/" target="_blank"><span style="color:#800080;">Bodine Electric Company </span></a>©  11/2010.  All rights reserved. </span></p>
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			<media:title type="html">Bodine Gearmotors</media:title>
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			<media:title type="html">Sensorless Brushless DC Controls / Back EMF with sensors aligned</media:title>
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			<media:title type="html">Sensorless BLDC Controls / Motor Back-EMF with drive PWM Noise </media:title>
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			<media:title type="html">Bodine INTEGRAmotor - BLDC (ECM) Motors and Gearmotors</media:title>
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		<title>Application Tips: Troubleshooting a Brushless DC (ECM) Motor and Control System</title>
		<link>http://gearmotorblog.wordpress.com/2010/11/18/bodine-bldc-application-tips/</link>
		<comments>http://gearmotorblog.wordpress.com/2010/11/18/bodine-bldc-application-tips/#comments</comments>
		<pubDate>Thu, 18 Nov 2010 16:30:10 +0000</pubDate>
		<dc:creator>Edmund Glueck</dc:creator>
				<category><![CDATA[Distributor News]]></category>
		<category><![CDATA[Engineering Talk]]></category>
		<category><![CDATA[Bodine Electric Company]]></category>
		<category><![CDATA[Brushless DC Gearmotor]]></category>
		<category><![CDATA[Distribution/Channel News]]></category>
		<category><![CDATA[Fractional Horsepower]]></category>
		<category><![CDATA[Gearmotor]]></category>
		<category><![CDATA[Gearmotors]]></category>

		<guid isPermaLink="false">http://gearmotorblog.wordpress.com/?p=490</guid>
		<description><![CDATA[One of our authorized distributors called our Tech Support staff in Chicago recently because his customer was having problems with a Bodine 34B4BEBL brushless DC motor and our ABL-3911 control. Our products were designed into a new machine that is used to induction-harden steel shafts. 1) Because of the distance between the motor and the control, the [...]<img alt="" border="0" src="http://stats.wordpress.com/b.gif?host=gearmotorblog.wordpress.com&amp;blog=8758402&amp;post=490&amp;subd=gearmotorblog&amp;ref=&amp;feed=1" width="1" height="1" />]]></description>
			<content:encoded><![CDATA[<div class="mceTemp" style="text-align:left;">
<div id="attachment_501" class="wp-caption alignleft" style="width: 239px"><a href="http://gearmotorblog.files.wordpress.com/2010/11/bldc-mtr-ctrl-systems_blog_11-12-2010_25.jpg"><img class="size-medium wp-image-501" title="Bodine Brushless DC (BLDC) Gearmotors, Motors and Controls" src="http://gearmotorblog.files.wordpress.com/2010/11/bldc-mtr-ctrl-systems_blog_11-12-2010_25.jpg?w=229&#038;h=300" alt="Bodine Brushless DC (BLDC) Gearmotors, Motors and Controls" width="229" height="300" /></a><p class="wp-caption-text">Bodine Brushless DC (BLDC) Gearmotors, Motors and Controls</p></div>
<p>One of our authorized distributors called our Tech Support staff in Chicago recently because his customer was having problems with a Bodine 34B4BEBL brushless DC motor and our ABL-3911 control. Our products were designed into a new machine that is used to induction-harden steel shafts.</p>
</div>
<p style="text-align:left;">1) Because of the distance between the motor and the control, the <strong>customer had made his own wiring harness </strong>instead of using a pre-made cable kit, like our model 3983. Because of a termination error with their home-made wire harness, they connected the signal common to earth ground and destroyed one control. Not only did they blow up an IC on the control board but they also damaged a Hall effect sensor in the motor.</p>
<p>2) The problem they were having was that when the control was turned on, the <strong>motor would not rotate</strong>. The motor shaft just vibrated in place. This can be the case when the motor phases are energized in the wrong sequence. We asked the distributor to make sure that the Hall effect sensor wires weren&#8217;t connected wrong. We also suggested that one way they could rule out the possibility of the homemade cable having any shorts or wrong connections in it would be to use Bodine&#8217;s Model 3983 cable kit just for testing. If the motor and control operated properly with our Model 3983, then we would know that the homemade cable was the source of the problem. However, the customer insisted that they had already checked and double-checked their wiring and that it was correct.</p>
<div id="attachment_525" class="wp-caption alignright" style="width: 273px"><a href="http://gearmotorblog.files.wordpress.com/2010/11/bldc_connections_blog_11-2010.jpg"><img class="size-full wp-image-525" title="Brushless DC Motor Connections" src="http://gearmotorblog.files.wordpress.com/2010/11/bldc_connections_blog_11-2010.jpg?w=500" alt="Brushless DC Motor Connections"   /></a><p class="wp-caption-text">Brushless DC Motor Connections</p></div>
<p>3) Fortunately, our distributor checked it as well, and found that <strong>two wires had indeed been crossed</strong>. After this had been corrected, a new problem showed up. Now the customer reported that when they turned the control on, the motor sped up by itself and then stopped by itself. It wouldn&#8217;t start again after that. At this point, the distributor asked our Tech Support staff member to join him at the customer&#8217;s plant.</p>
<p>4) We looked the system over and confirmed that it wouldn&#8217;t start. We <strong>checked the dip switches </strong>and confirmed that they were in the proper positions for the motor that was being used. We asked if either of the fuses was blown. <strong>The customer insisted that they&#8217;d checked the fuses </strong>and that they were fine. Again, the distributor checked as well and found a blown control fuse. We replaced the fuse and turned the control on. The motor sped up by itself and after a while stopped by itself just as the customer had described. The motor fuse was blown again. We now also realized that the acceleration potentiometer was turned fully clockwise (for longest acceleration time) which made it seem that the motor was speeding up by itself. In actuality, it was just taking a long time for the motor to accelerate to the set speed. We then turned our attention to <strong>the fuse that kept blowing</strong>.</p>
<p>5) We explained to the customer that Bodine&#8217;s ABL-3911 control, when configured for our 34B4BEBL BLDC motor, uses a 2 amp motor fuse and that, since the fuse is blowing, the motor must be drawing more than 2 amps for an extended period. Since current draw is directly proportional to the motor load for a brushless DC motor, <strong>the motor must be overloaded</strong>. We put a new fuse in and measured the current draw. The motor was drawing 4 amps. We also noted that the current increased significantly as we increased the motor speed, which led us to question the suitability of the <strong>customer’s load bearing </strong>for high speed operation. We checked the bearing and the chain between the motor and the load.</p>
<p>6) The chain was so tight that we could not budge it. When they loosened the chain, the current dropped down to 2 amps. The bearing they were using was not lubricated and seemed to be misaligned. When it was <strong>replaced with a lubricated bearing</strong>, the current dropped to less than 1 amp. We now had a happy customer who could demonstrate his new machine to his customer.</p>
<p>This is not the first application support call where the motor and control were blamed for a problem when, in fact, the problem was just a symptom of the true problem.</p>
<p><strong><span style="color:#0000ff;">To identify and solve the root-cause of the problem, we did the following: </span>(1) we checked and corrected the wire connections, (2) we confirmed that the control’s dip switches were set properly, (3) we checked and replaced blown fuses, (4) we measured the current draw of the motor under load and determined that it was overloaded, and (5) we identified ways to reduce the load.</strong></p>
<p style="text-align:center;"><strong></strong>Copyright  <a title="Bodine Electric Company Home Page" href="http://www.bodine-electric.com/" target="_blank">Bodine Electric Company </a>©  11/2010.  All rights reserved</p>
<div class="mceTemp mceIEcenter" style="text-align:center;">
<dl class="wp-caption aligncenter">
<dt class="wp-caption-dt"><a href="http://gearmotorblog.files.wordpress.com/2010/11/control-group_low-for-sales-conference_blog.jpg"><img class="size-full wp-image-512" title="Bodine Motion Controls - Designed &amp; Manufactured in Chicago (USA)" src="http://gearmotorblog.files.wordpress.com/2010/11/control-group_low-for-sales-conference_blog.jpg?w=500&#038;h=278" alt="Bodine Motion Controls for Brushless DC and PMDC (FHP) gearmotors and motors" width="500" height="278" /></a></dt>
<dd class="wp-caption-dd">Motion Controls for Brushless DC and PMDC (FHP) gearmotors and motors:  Designed &amp; Manufactured in Chicago (U.S.A.)</dd>
</dl>
<p>Contact us at: <a href="mailto:info@bodine-electric.com">info@bodine-electric.com</a></p>
</div>
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			<media:title type="html">Bodine Gearmotors</media:title>
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			<media:title type="html">Bodine Brushless DC (BLDC) Gearmotors, Motors and Controls</media:title>
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			<media:title type="html">Brushless DC Motor Connections</media:title>
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			<media:title type="html">Bodine Motion Controls - Designed &#38; Manufactured in Chicago (USA)</media:title>
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		<title>Over 100 Metric Bodine Gearmotors &amp; Motors Now Available Online</title>
		<link>http://gearmotorblog.wordpress.com/2010/11/01/metric-bodine-gearmotors-now-available-online/</link>
		<comments>http://gearmotorblog.wordpress.com/2010/11/01/metric-bodine-gearmotors-now-available-online/#comments</comments>
		<pubDate>Mon, 01 Nov 2010 21:45:46 +0000</pubDate>
		<dc:creator>Edmund Glueck</dc:creator>
				<category><![CDATA[Company News]]></category>
		<category><![CDATA[Distributor News]]></category>
		<category><![CDATA[Standard Products]]></category>
		<category><![CDATA[AC Gearmotor]]></category>
		<category><![CDATA[Bodine Electric Company]]></category>
		<category><![CDATA[Distribution/Channel News]]></category>
		<category><![CDATA[Fractional Horsepower]]></category>
		<category><![CDATA[Gearmotor]]></category>
		<category><![CDATA[Gearmotors]]></category>
		<category><![CDATA[Permanent Magnet DC Gearmotors]]></category>

		<guid isPermaLink="false">http://gearmotorblog.wordpress.com/?p=441</guid>
		<description><![CDATA[Metric Motors and Gearmotors from Bodine Electric Company (USA) Our selection of metric AC induction and permanent magnet DC products features special motor windings for many international markets and 50Hz applications. These gearmotors and motors also feature metric drive shafts and metric mounting threads. Fixed speed AC motors are available with permanent split capacitor, split-phase, [...]<img alt="" border="0" src="http://stats.wordpress.com/b.gif?host=gearmotorblog.wordpress.com&amp;blog=8758402&amp;post=441&amp;subd=gearmotorblog&amp;ref=&amp;feed=1" width="1" height="1" />]]></description>
			<content:encoded><![CDATA[<div class="mceTemp mceIEcenter" style="text-align:center;">
<dl class="wp-caption aligncenter">
<dt class="wp-caption-dt"><a href="http://gearmotorblog.files.wordpress.com/2010/11/metric-grp-from-landing-page.jpg"><img class="size-full wp-image-439" title="Metric Motors and Gearmotors from Bodine Electric Company (USA)" src="http://gearmotorblog.files.wordpress.com/2010/11/metric-grp-from-landing-page.jpg?w=500&#038;h=315" alt="" width="500" height="315" /></a></dt>
<dd class="wp-caption-dd">Metric Motors and Gearmotors from Bodine Electric Company (USA)</dd>
</dl>
</div>
<p>Our selection of metric <a title="Metric AC Gearmotors and Motors from Bodine" href="http://www.bodine-electric.com/Asp/ProductGroup.asp?Context=46" target="_blank">AC induction </a>and <a title="Metric PMDC Gearmotors and Motors from Bodine" href="http://www.bodine-electric.com/Asp/ProductGroup.asp?Context=47" target="_blank">permanent magnet DC </a>products features special motor windings for many international markets and 50Hz applications. These gearmotors and motors also feature metric drive shafts and metric mounting threads.</p>
<p><strong>Fixed speed AC motors </strong>are available with permanent split capacitor, split-phase, and three-phase windings. AC metric motors are rated 230 VAC, 50 Hz, single-phase, or 230/400 VAC, 50Hz, three-phase. <strong>Permanent magnet DC motors </strong>are available with a voltage rating of 180 VDC (F.F.=1.6, designed for continuous duty operation). Custom AC and DC windings can be provided to match almost any international rating.</p>
<p>We offer a complete line of both AC and DC metric <strong>right-angle and parallel shaft gearmotors</strong>. Torque output for AC gearmotors and motors ranges from 0.021-43 Nm. Fixed-speed models are available with speeds from 7-280 1/min (revolutions per minute). Output torque for our PMDC products ranges from 0.18-43 Nm with rated speed range from 5.8-345 1/min (rpm).</p>
<div class="mceTemp">
<div class="mceTemp">
<div id="attachment_464" class="wp-caption alignleft" style="width: 295px"><a href="http://gearmotorblog.files.wordpress.com/2010/11/upm-1865_chassis_enclosed_25-e1288816993386.jpg"><img class="size-medium wp-image-464" title="Bodine PMDC Motor Speed Controls Model 0865, 0866, 1865" src="http://gearmotorblog.files.wordpress.com/2010/11/upm-1865_chassis_enclosed_25-e1288816993386.jpg?w=285&#038;h=300" alt="Bodine PMDC Motor Speed Controls Model 0865, 0866, 1865 (0-180VDC)" width="285" height="300" /></a><p class="wp-caption-text">Bodine PMDC Motor Speed Controls Model 0865, 0866, 1865 (0-180VDC, at 230VAC)</p></div>
<p>Our 180 VDC metric PMDC motors and gearmotors are designed to operate with filtered and unfiltered PMDC motor speed controls and are rated for either F.F.=1.0 or 1.6. Bodine Electric Company also manufactures DC motor speed controls for these 180VDC gearmotors and motors. Our type &#8220;UPM&#8221; stock models, 0865 and 0866, are unfiltered SCR speed controls that operate from a 115/230, 50/60Hz input and can provide either 0-90VDC (at 115VAC input), or 0-180VDC (at 230VAC input). Bodine also offers an enclosed version of this DC motor control; see stock model 1865.</p>
</div>
</div>
<p> </p>
<p><a title="Inverter Duty, Variable Speed AC Gearmotors (non-metric)" href="http://www.bodine-electric.com/Asp/ProductGroup.asp?Context=6" target="_blank">Pacesetter™ AC variable speed</a>, inverter duty, three-phase gearmotors and motors are available in non-metric versions only, but can be operated with a 230/50Hz inverter (AC variable frequency drive) when the drive&#8217;s motor output frequency is set for 60Hz motors.</p>
<p>These gearmotors and motors are also available through Bodine Electric&#8217;s <a title="Authorized Bodine Distributors" href="http://www.bodine-electric.com/Asp/Distribuloc.asp" target="_blank">worldwide distributor network</a>. The standard lead-time for our metric models is 4 weeks.</p>
<p><strong>Explore:  </strong><a href="http://www.bodine-electric.com/Asp/ProductGroup.asp?Context=46">Metric AC Motors and Gearmotors</a>; <a href="http://www.bodine-electric.com/Asp/ProductGroup.asp?Context=47">Metric PMDC Motors and Gearmotors</a>; DC Speed Control Models: <a href="http://www.bodine-electric.com/products/productlocator/productlocator.asp?model=0865">0865</a>,  <a href="http://www.bodine-electric.com/products/productlocator/productlocator.asp?model=0866">0866</a>,  <a href="http://www.bodine-electric.com/products/productlocator/productlocator.asp?model=1865">1865</a>; <a href="http://www.bodine-electric.com/Asp/ProductGroup.asp?Context=6">Pacesetter AC Inverter Duty Gearmotors</a>;  <a href="http://www.bodine-electric.com/CustomSolutions/">Custom Options and Solutions</a></p>
<p style="text-align:center;">Copyright  <a title="Bodine Electric Company Home Page" href="http://www.bodine-electric.com/" target="_blank">Bodine Electric Company </a>©  11/2010.  All rights reserved.</p>
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			<media:title type="html">Bodine Gearmotors</media:title>
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			<media:title type="html">Metric Motors and Gearmotors from Bodine Electric Company (USA)</media:title>
		</media:content>

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			<media:title type="html">Bodine PMDC Motor Speed Controls Model 0865, 0866, 1865</media:title>
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		<title>Bodine’s New WX Gearmotors &#8211; 100+ New Stock Models</title>
		<link>http://gearmotorblog.wordpress.com/2010/05/05/new-bodine-wx-gearmotors/</link>
		<comments>http://gearmotorblog.wordpress.com/2010/05/05/new-bodine-wx-gearmotors/#comments</comments>
		<pubDate>Wed, 05 May 2010 20:43:41 +0000</pubDate>
		<dc:creator>Edmund Glueck</dc:creator>
				<category><![CDATA[Company News]]></category>
		<category><![CDATA[Gearmotor Basics]]></category>
		<category><![CDATA[Standard Products]]></category>
		<category><![CDATA[AC Gearmotor]]></category>
		<category><![CDATA[Bodine Electric Company]]></category>
		<category><![CDATA[Brushless DC Gearmotor]]></category>
		<category><![CDATA[Distribution/Channel News]]></category>
		<category><![CDATA[Fractional Horsepower]]></category>
		<category><![CDATA[Gearmotors]]></category>
		<category><![CDATA[Permanent Magnet DC Gearmotors]]></category>

		<guid isPermaLink="false">http://gearmotorblog.wordpress.com/?p=387</guid>
		<description><![CDATA[We are pleased to introduce our new line of WX gearmotors. These new WX gearmotors were designed to provide longer life and higher performance than similar gearmotors in the same size range. The new WX gearmotors are designed to drive applications such as conveyor systems, packaging equipment, metering pumps, medical devices, commercial appliances, and solar [...]<img alt="" border="0" src="http://stats.wordpress.com/b.gif?host=gearmotorblog.wordpress.com&amp;blog=8758402&amp;post=387&amp;subd=gearmotorblog&amp;ref=&amp;feed=1" width="1" height="1" />]]></description>
			<content:encoded><![CDATA[<p>We are pleased to introduce our new line of <strong><a title="Over 100 New WX Gearmotors from Bodine" href="http://www.bodine-electric.com/wx/" target="_blank">WX gearmotors</a></strong>. These new WX gearmotors were designed to provide longer life and higher performance than similar gearmotors in the same size range. The new WX gearmotors are designed to drive applications such as conveyor systems, packaging equipment, metering pumps, medical devices, commercial appliances, and solar powered outdoor equipment.</p>
<p><span style="color:#0000ff;">The WX is a parallel shaft gearhead that can deliver up to 210 lb-in (24 Nm) continuous torque. This new gearhead complements Bodine’s smaller type D and Z gearheads that produce up to 120 lb-in (14 Nm) of continuous duty torque, and the larger type E/F, HG, and CG gearheads that range from 250 to 1000 lb-in (up to 113 Nm) of continuous torque.</span> </p>
<div id="attachment_383" class="wp-caption aligncenter" style="width: 501px"><a href="http://gearmotorblog.files.wordpress.com/2010/05/globalspec_wx_max-torque_rectgl_test.jpg"><img class="size-large wp-image-383" title="New Bodine WX Gearmotors" src="http://gearmotorblog.files.wordpress.com/2010/05/globalspec_wx_max-torque_rectgl_test.jpg?w=491&#038;h=403" alt="New Bodine WX Gearmotors" width="491" height="403" /></a><p class="wp-caption-text">New Bodine WX Gearmotors</p></div>
<p>The exterior of the new <strong>WX gearhead</strong> is identical to Bodine’s old type “W” gearmotor models, but the inside has been completely redesigned. These new WX gearmotors feature all-steel helical gear trains and synthetic lubricants, allowing the type 33A-WX (PMDC) and 34B-WX (BLDC) to produce up to 65% more torque than previous type “W” models. The new steel gearing is designed to AGMA 9 standards or higher, to assure the quiet operation that is expected from Bodine Electric products. The synthetic lubricant in this new gearhead improves efficiency, and allows these gearmotors to operate in a wide temperature range. 108 new stock models feature 12 available gear ratios, ranging from 4:1 to 312:1, and rated output speeds from 658 to 8 RPM.</p>
<p>As with most Bodine gearmotors, the new WX gearhead is offered <strong>with a range of motor options</strong> to provide customers with the flexibility and design solution that best fits their application needs. The WX  gearhead is stocked with a new AC fixed speed, 3-wire-reversible motor winding; two permanent magnet DC motor options, either rated 90/130 VDC or 12/24 VDC; and brushless DC WX models, type 34B-WX, are offered with a 24 VDC or 130 VDC winding option.</p>
<div id="attachment_423" class="wp-caption aligncenter" style="width: 509px"><a href="http://gearmotorblog.files.wordpress.com/2010/05/0995_wx-3-pt-mtg-adptr_wtext_05-05-2010.jpg"><img class="size-full wp-image-423" title="Bodine WX Accy Kit Model 0995 3-Point-Mtg Adaptor" src="http://gearmotorblog.files.wordpress.com/2010/05/0995_wx-3-pt-mtg-adptr_wtext_05-05-2010.jpg?w=500" alt="Bodine WX Accy Kit Model 0995 3-Point-Mtg Adaptor"   /></a><p class="wp-caption-text">Bodine WX Accy Kit Model 0995 3-Point-Mtg Adaptor</p></div>
<p style="text-align:left;"><strong>These new WX models are &#8220;cURus&#8221; marked, and are designed and manufactured to be RoHS compliant. All new WX stock models can be configured to feature a 3-hole mounting pattern via a simple bolt-on adaptor plate (which allows the WX to be a drop-in replacement for similar gearmotors from other manufacturers).</strong></p>
<div id="attachment_384" class="wp-caption alignleft" style="width: 190px"><a href="http://gearmotorblog.files.wordpress.com/2010/05/34r-ac-wx_square_3_wlogo_10-27-09_50.jpg"><img class="size-medium wp-image-384 " title="Bodine 34R-WX AC Fixed-Speed Gearmotor" src="http://gearmotorblog.files.wordpress.com/2010/05/34r-ac-wx_square_3_wlogo_10-27-09_50.jpg?w=180&#038;h=180" alt="Bodine 34R-WX AC Fixed-Speed Gearmotor" width="180" height="180" /></a><p class="wp-caption-text">Bodine 34R-WX AC Fixed-Speed Gearmotor</p></div>
<p style="text-align:left;"><strong><span style="color:#0000ff;">34R-WX [AC]:</span></strong> The WX gearhead is the first gearhead to be paired with Bodine’s new <strong>3-wire reversible 34R </strong>(4 inch/100 mm diameter), single phase<strong>, 1/7 HP (107 Watts)</strong> motor winding. The three-wire configuration simplifies connection, and makes reversing the motor’s direction simply a matter of switching the position of two leads. This new winding can also operate at 50 Hz by utilizing a different value run capacitor. A new 230VAC, 50/60Hz, 1-phase, 3-wire reversible winding is also available for custom configurations.</p>
<div id="attachment_386" class="wp-caption alignright" style="width: 190px"><a href="http://gearmotorblog.files.wordpress.com/2010/05/bod_34b_wx_logo_large.jpg"><img class="size-medium wp-image-386 " title="Bodine 34B-WX Brushless DC (ECM) Gearmotor" src="http://gearmotorblog.files.wordpress.com/2010/05/bod_34b_wx_logo_large.jpg?w=180&#038;h=180" alt="Bodine 34B-WX Brushless DC (ECM) Gearmotor" width="180" height="180" /></a><p class="wp-caption-text">Bodine 34B-WX Brushless DC (ECM) Gearmotor</p></div>
<p style="text-align:left;"><strong><span style="color:#008000;">34B-WX [BLDC]:</span></strong> The WX gearhead is available with Bodine’s type<strong> 34B, TENV</strong>,<strong> 1/5HP (149 Watts) brushless DC motors. </strong>These electronically commutated (BLDC) motors require less maintenance and last longer than traditional brush-type PMDC motors. The brushless construction results in a cooler running, quieter motor that can accelerate and decelerate quickly. They can be used in place of brush-type motors in applications where <strong><em>high starting torque and linear speed-torque characteristics</em></strong> are critical. The new 34B-WX gearmotors are offered with 130VDC and 24VDC windings and are available with or without accessory shafts for external encoder or brake installation.</p>
<div id="attachment_385" class="wp-caption alignleft" style="width: 190px"><a href="http://gearmotorblog.files.wordpress.com/2010/05/bod_33a_wx_logo_large.jpg"><img class="size-medium wp-image-385 " title="Bodine 33A-WX PMDC Gearmotor" src="http://gearmotorblog.files.wordpress.com/2010/05/bod_33a_wx_logo_large.jpg?w=180&#038;h=180" alt="Bodine 33A-WX PMDC Gearmotor" width="180" height="180" /></a><p class="wp-caption-text">Bodine 33A-WX PMDC Gearmotor</p></div>
<p><strong><span style="color:#ff6600;">33A-WX [PMDC]:</span></strong> The WX gearhead is also available with <strong>Bodine’s 33A-frame permanent magnet DC, 1/4-1/11 HP motors. </strong>These motors provide high starting torque and linear speed torque characteristics. The 33A-frame motors feature permanently lubricated ball bearing construction for maintenance-free operation, as well heavy gauge steel housing and copper graphite brushes. The windings are resin-impregnated. Bodine PMDC motors feature an unique skewed armature design to minimize cogging and operate quietly over the full speed range.</p>
<p style="text-align:center;"> </p>
<div id="attachment_391" class="wp-caption aligncenter" style="width: 310px"><a href="http://gearmotorblog.files.wordpress.com/2010/05/quickdelivery_silvertext-01_12-18-2009_50.jpg"><img class="size-medium wp-image-391" title="Bodine Quick Delivery Program for Stock Gearmotors" src="http://gearmotorblog.files.wordpress.com/2010/05/quickdelivery_silvertext-01_12-18-2009_50.jpg?w=300&#038;h=91" alt="Bodine Quick Delivery Program for Stock Gearmotors" width="300" height="91" /></a><p class="wp-caption-text">Bodine Quick Delivery Program for Stock Gearmotors</p></div>
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<td>All type &#8220;WX&#8221; gearmotors are now available through our new <strong>Quick Delivery</strong> program. This program is designed to ship customer orders in small order quantities within two to three business days. Products will be maintained in stock, or assembled to order via a quick-turn production cell. Larger order quantities will require lead-time. Expedited delivery options are also available.</td>
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<p style="text-align:left;"> </p>
<p style="text-align:left;"><strong>The New Bodine type WX Gearmotors. For additional information, <a title="Bodine WX Gearmotors" href="http://www.bodine-electric.com/wx" target="_self">click here</a>… </strong></p>
<p>Copyright  <a title="Bodine Electric Company Home Page" href="http://www.bodine-electric.com" target="_blank">Bodine Electric Company </a>©  05/2010.  All rights reserved.</p>
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		<title>Bodine Motor Windings &#8211; Standard and Custom Options</title>
		<link>http://gearmotorblog.wordpress.com/2010/03/04/bodine-motor-windings/</link>
		<comments>http://gearmotorblog.wordpress.com/2010/03/04/bodine-motor-windings/#comments</comments>
		<pubDate>Thu, 04 Mar 2010 17:41:14 +0000</pubDate>
		<dc:creator>Edmund Glueck</dc:creator>
				<category><![CDATA[Custom Solutions]]></category>
		<category><![CDATA[Engineering Talk]]></category>
		<category><![CDATA[Standard Products]]></category>
		<category><![CDATA[AC Gearmotor]]></category>
		<category><![CDATA[Bodine Electric Company]]></category>
		<category><![CDATA[Brushless DC Gearmotor]]></category>
		<category><![CDATA[Fractional Horsepower]]></category>
		<category><![CDATA[Gearmotor]]></category>
		<category><![CDATA[Gearmotors]]></category>
		<category><![CDATA[Permanent Magnet DC Gearmotors]]></category>
		<category><![CDATA[Variable Speed AC Motors]]></category>

		<guid isPermaLink="false">http://gearmotorblog.wordpress.com/?p=297</guid>
		<description><![CDATA[Bodine Electric Company offers a range of standard gearmotors and motors with the most common voltage and frequency ratings for both the North American and International markets.  As a manufacturer that exclusively focuses on fractional horsepower (less than 1HP/746 Watts) products, Bodine Electric also has the engineering expertise to design and manufacture a great variety of custom winding [...]<img alt="" border="0" src="http://stats.wordpress.com/b.gif?host=gearmotorblog.wordpress.com&amp;blog=8758402&amp;post=297&amp;subd=gearmotorblog&amp;ref=&amp;feed=1" width="1" height="1" />]]></description>
			<content:encoded><![CDATA[<p><strong><span style="color:#000080;">Bodine Electric Company offers a range of standard gearmotors and motors with the most common voltage and frequency ratings for both the North American and International markets.</span></strong> </p>
<p><strong><span style="color:#000080;">As a manufacturer that exclusively focuses on fractional horsepower (less than 1HP/746 Watts) products, Bodine Electric also has the engineering expertise to design and manufacture a great variety of custom winding types and ratings.</span></strong> </p>
<p><strong>AC Induction motor windings</strong>:  are available in single-phase, two-phase and poly-phase (three-phase) designs including the following types; split-phase (with centrifugal start switch), capacitor start, permanent split capacitor, 2 capacitor start, 2 capacitor start/one capacitor run, and reluctance synchronous. These windings can be produced in 2-, 4-, 6- &amp; 8-pole configurations and can be rated as continuous duty, intermittent duty, inverter duty, dual voltage, dual frequency and multi-speed. Our windings are available in voltages ranging from 12 to 575 VAC. Bodine Electric also provides solutions for OEM applications that require thermal overload protectors with manual or automatic resets, or simple temperature limiting switches. </p>
<div id="attachment_306" class="wp-caption aligncenter" style="width: 510px"><a href="http://gearmotorblog.files.wordpress.com/2010/03/ac-motor-stators_in-process_finished_small.jpg"><img class="size-full wp-image-306" title="AC Motor Stators - In-Process and Finished (Bodine Electric Company)" src="http://gearmotorblog.files.wordpress.com/2010/03/ac-motor-stators_in-process_finished_small.jpg?w=500&#038;h=190" alt="AC Motor Stators - In-Process and Finished (Bodine Electric Company)" width="500" height="190" /></a><p class="wp-caption-text">AC Motor Stators - In-Process and Finished (Bodine Electric Company)</p></div>
<p><strong>Features/Benefits of various AC Motor and Gearmotor Designs:   </strong>This table was created to help you better understand the capabilities, advantages, and disadvantages of the numerous AC motor and gearmotor windings that are offered by Bodine Electric Company. Click on this link to learn more about our range of available AC motor windings:  </p>
<div class="mceTemp mceIEcenter" style="text-align:left;">
<p><a href="http://www.bodine-electric.com/Products/Asp/ACMotorAdvantages.asp">http://www.bodine-electric.com/Products/Asp/ACMotorAdvantages.asp</a> </p>
<div class="mceTemp mceIEcenter" style="text-align:left;"> </div>
<div class="mceTemp mceIEcenter" style="text-align:left;"><strong>Permanent magnet DC motors:</strong> are available with rated voltages from 12 to 240 VDC. They can be designed in 2 &amp; 4 pole versions and in lap or wave (4 brush vs. 2 brush) configurations. Multiple magnet grades are available for enhanced performance or added demagnetization protection. End-of-life signaling brushes, and a new proprietary brush wear sensor system are also available from Bodine Electric Company. </div>
<div class="wp-caption aligncenter" style="width: 509px"><a href="http://gearmotorblog.files.wordpress.com/2010/03/dc-armature_in-process_finished_small.jpg"><strong><img class="size-full wp-image-307  " title="DC Motor Armature – Finished and In-Process (Bodine Electric Company)" src="http://gearmotorblog.files.wordpress.com/2010/03/dc-armature_in-process_finished_small.jpg?w=500" alt="DC Motor Armature – In-Process and Finished (Bodine Electric Company)"   /></strong></a><p class="wp-caption-text">DC Motor Armature – Finished and In-Process (Bodine Electric Company)</p></div>
<p><span style="color:#000080;"> </span></p>
<p><strong>Brushless DC (ECM) motor windings: </strong> Similar options and winding configurations are available for Bodine Electric’s growing line of Brushless DC (electronically commutated) motors and gearmotors. Our standard brushless DC windings are 3-phase, 4-pole designs (standard voltages are 24 VDC and 130 VDC).  Bodine Electric Company introduced the first BLDC motors, gearmotors and motor speed controls in the 1980s. Since then, we have expanded our product offering to a wide selection of custom designs with voltages ranging from 12 VDC to 260 VDC, and horsepower ratings up to 1HP/746W (our new type 48B motors/gearmotors). In addition, we offer our unique 24VDC <a href="http://www.bodine-electric.com/choice/" target="_blank">INTEGRAmotor</a>™ product line of brushless DC motors with built-in motor speed control and motor feedback device; and our innovative direct drive <a href="http://www.bodine-electric.com/etorq/" target="_blank">e-TORQ</a>™ motor technology. Our standard 7-inch diameter e-TORQ motor is a 8-pole machine, the larger 14-inch diameter motor features a 16-pole winding.</p>
<div><span style="color:#000080;"></span></div>
<p><span style="color:#000080;"></p>
<div id="attachment_323" class="wp-caption aligncenter" style="width: 448px"><a href="http://gearmotorblog.files.wordpress.com/2010/03/34b_cutaway_bycliff_07-2008_wht_cropped_50.jpg"><img class="size-full wp-image-323" title="Bodine Type 34B Brushless DC Motor (cutaway view)" src="http://gearmotorblog.files.wordpress.com/2010/03/34b_cutaway_bycliff_07-2008_wht_cropped_50.jpg?w=500" alt="Bodine Type 34B Brushless DC Motor (cutaway view)"   /></a><p class="wp-caption-text">Bodine Type 34B Brushless DC Motor (cutaway view)</p></div>
<p><span style="color:#000080;"> </span></p>
<p><span style="color:#000080;"><strong>Bodine Electric Company designs, develops, and manufactures all offered motor windings &#8211; AC and BLDC stators, and DC motor armatures.</strong></span></p>
<p></span></p>
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<p style="text-align:left;"><strong> </strong></p>
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<div id="attachment_294" class="wp-caption aligncenter" style="width: 510px"><a href="http://gearmotorblog.files.wordpress.com/2010/03/dc-armature-winder_peo_10-15-09_25.jpg"><strong><img class="size-full wp-image-294 " title="DC Motor Armature - Winding Cell (Bodine Peosta Plant)" src="http://gearmotorblog.files.wordpress.com/2010/03/dc-armature-winder_peo_10-15-09_25.jpg?w=500&#038;h=374" alt="DC Motor Armature - Winding Equipment (Bodine Peosta Plant)" width="500" height="374" /></strong></a><p class="wp-caption-text">DC Motor Armature - Winding Cell (Bodine Peosta Plant)</p></div>
<p><strong> </strong></p>
<p><strong> Learn more about our full range of products at: </strong><a href="http://www.bodine-electric.com"><strong>www.bodine-electric.com</strong></a><strong>  </strong></p>
<p style="text-align:left;"><strong>  </strong></p>
<p style="text-align:center;">
<div id="attachment_293" class="wp-caption aligncenter" style="width: 429px"><a href="http://gearmotorblog.files.wordpress.com/2010/03/ac-winding_in-process_cropped_25.jpg"><strong><img class="size-full wp-image-293    " title="AC &amp; BLDC Motor Stator In Process - Winding Cell (Bodine Peosta Plant)" src="http://gearmotorblog.files.wordpress.com/2010/03/ac-winding_in-process_cropped_25.jpg?w=500" alt="AC Motor Stator In Process - Winding Equipment (Bodine Peosta Plant)"   /></strong></a><p class="wp-caption-text">AC &amp; BLDC Motor Stator In Process - Winding Cell (Bodine Peosta Plant)</p></div>
<p>Copyright  <a title="Bodine AC Gearmotors and Motors" href="http://www.bodine-electric.com/Asp/ProductMenu.asp" target="_blank">Bodine Electric Company </a>©  03/2010.  All rights reserved.</p>
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			<media:title type="html">AC &#38; BLDC Motor Stator In Process - Winding Cell (Bodine Peosta Plant)</media:title>
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		<title>&#8220;Hotrodding&#8221; AC Capacitor Motors and Gearmotors &#8230;At your own Risk</title>
		<link>http://gearmotorblog.wordpress.com/2010/01/26/hotrodding-capacitor-motors/</link>
		<comments>http://gearmotorblog.wordpress.com/2010/01/26/hotrodding-capacitor-motors/#comments</comments>
		<pubDate>Tue, 26 Jan 2010 18:03:43 +0000</pubDate>
		<dc:creator>Edmund Glueck</dc:creator>
				<category><![CDATA[Custom Solutions]]></category>
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		<description><![CDATA[You can get higher starting torque from an AC induction motor by replacing factory specified capacitors with larger ones.  But pushing the motor too far beyond design specs is risky.  Here’s how capacitance affects motor performance.     Overview Capacitors for permanent-split-capacitor (PSC) and capacitor-start (CS) AC induction motors are sized by motor manufacturers to produce [...]<img alt="" border="0" src="http://stats.wordpress.com/b.gif?host=gearmotorblog.wordpress.com&amp;blog=8758402&amp;post=225&amp;subd=gearmotorblog&amp;ref=&amp;feed=1" width="1" height="1" />]]></description>
			<content:encoded><![CDATA[<div><strong>You can get higher starting torque from an AC induction motor by replacing factory specified capacitors with larger ones.  But pushing the motor too far beyond design specs is risky.  Here’s how capacitance affects motor performance.</strong><strong> </strong><strong> </strong></div>
<div><strong> </strong></div>
<div><strong>Overview</strong></div>
<div id="attachment_237" class="wp-caption alignright" style="width: 310px"><a href="http://gearmotorblog.files.wordpress.com/2010/01/bodineac-motors_tenv_blue-bkgr_blog.jpg"><img class="size-medium wp-image-237" title="Permanent Split Capacitor (PSC) Motors, Bodine Electric Company" src="http://gearmotorblog.files.wordpress.com/2010/01/bodineac-motors_tenv_blue-bkgr_blog.jpg?w=300&#038;h=204" alt="Permanent Split Capacitor (PSC) Motors, Bodine Electric Company" width="300" height="204" /></a><p class="wp-caption-text">Permanent Split Capacitor (PSC) Motors, Bodine Electric Company</p></div>
<p>Capacitors for permanent-split-capacitor (PSC) and capacitor-start (CS) AC induction motors are sized by motor manufacturers to produce adequate starting torque for most fractional-horsepower (FHP) applications.  To increase starting torque, users sometimes replace factory-installed capacitors with larger ones.  But tampering with recommended capacitances could adversely affect some important motor parameters such as starting current and running efficiency.  If these parameters get too far out of line with motor-design specifications, windings overheat and ultimately burn out.  Here’s how PSC and CS motors operate, and how changes in capacitance affect motor performance.</p>
<p><strong>Capacitor Start Motors</strong></p>
<p>The CS motor is essentially a <span style="text-decoration:underline;">split-phase</span> motor with a capacitor for starting (see our <a title="Bodine Catalog S-16" href="http://www.bodine-electric.com/literature/s16/asp/AboutCatalog.asp" target="_blank">catalog S-16</a>, page 43, or the <a title="The Bodine Handbook" href="http://www.bodine-electric.com/TechTools/" target="_blank">Bodine Handbook</a> for additional info).  The motor has two windings:  a main or run winding, and an auxiliary or start winding.  The start winding is used only for starting the motor.  The run winding is energized for starting and running.  Because of the capacitor is in the start winding, currents in the two windings are out-of-phase.  This out-of-phase relationship sets up a rotating magnetic field that starts the rotor turning.  When the motor accelerates to approximately 70% of its normal operating speed, the start winding and capacitor circuit are disconnected by a speed-sensitive centrifugal switch, a current-sensing relay, or other means.</p>
<div id="attachment_238" class="wp-caption alignleft" style="width: 260px"><a href="http://gearmotorblog.files.wordpress.com/2010/01/capacitors_handbook_01_blog.jpg"><img class="size-full wp-image-238     " title="Motor Run Capacitors from Bodine Electric (Electrolytic, Film-, Oil-Type)" src="http://gearmotorblog.files.wordpress.com/2010/01/capacitors_handbook_01_blog.jpg?w=500" alt="Motor Run Capacitors from Bodine Electric (Electrolytic, Film, Oil-Type)"   /></a><p class="wp-caption-text">Motor Capacitors for Fractional Horsepower Motors and Gearmotors (left to right: Electrolytic, Film-, Oil-Type)</p></div>
<p>The capacitor value has no effect on the running performance of the CS motor.  However, starting torque and current both increase with capacitance.  Motor manufacturers select capacitor values to meet the starting torque requirements of typical applications without exceeding the current capabilities of the motor and its circuits.  Typical CS motors have capacitors that produce maximum starting torques of about four times the full-load running torque.  If more starting torque is required and if the motor circuit can safely provide additional current, some users replace the manufacturer’s standard-rated capacitor with one of greater capacitance.  However, this is usually done at the expense of other parameters.  And if the capacitance increase is excessive, starting torque may actually be reduced.</p>
<p>For a typical 1/15 hp CS motor, a capacitor with double the capacitance of the rated capacitor will only increase starting torque 50%, and starting current is almost doubled.  For some circuits, this increase in starting current may be unacceptable.  Other equipment such as lights on the same branch circuit with large motors may be affected by possible line-voltage drop.  Also, the life and reliability of the winding and centrifugal switch or starting relay in the motor is reduced by increased current.</p>
<p>Because the capacitor is connected only while starting, its duty cycle is highly intermittent.  Thus, the capacitor can be an inexpensive and relatively small AC electrolytic or metalized film type.  A normal, non-polarized, AC electrolytic capacitor consists of two aluminum plates separated by a porous paper which is saturated with an electrolyte.  Because these capacitors are not designed for continuous duty, the maximum on-time should not exceed 3 seconds and the maximum number of 3-second starts should generally not exceed 20 per hour (metalized film type capacitors are available for continuous duty operation).  However, most applications start in less than 3 seconds so that the number of starts can be increased in proportion to the decrease in starting time.  For example, a typical 0.5-second start permits the motor to be started 120 times per hour.</p>
<p>If the number of starts is too frequent or too long, windings and capacitors will overheat and motor reliability will decrease.  In such cases, a Permanent-Split-Capacitor motor should be used.  Also, PSC motors are more suitable for applications where frequent reversing is required, since the CS motor is reversible only from its rest position because of the starting switch.</p>
<p><strong>Permanent-Split-Capacitor Motors</strong></p>
<div id="attachment_244" class="wp-caption alignright" style="width: 285px"><a href="http://gearmotorblog.files.wordpress.com/2010/01/mylar-pp-run-capacitors_blog.jpg"><img class="size-full wp-image-244" title="Motor Run Capacitors (plastic box type); Metallized Polypropylene Film." src="http://gearmotorblog.files.wordpress.com/2010/01/mylar-pp-run-capacitors_blog.jpg?w=500" alt="Motor Run Capacitors (plastic box type); Metallized Polypropylene Film."   /></a><p class="wp-caption-text">Motor Run Capacitors (plastic box type); Metallized Polypropylene Film.</p></div>
<p>A Permanent-Split-Capacitor motor is similar to a CS motor and also contains two windings:  a main winding and a capacitor winding.  In a PSC motor, however, the capacitor winding is permanently connected in series with an AC oil-type or metallized film capacitor.  Unlike the CS motor, the auxiliary winding and capacitor are energized during both starting and running.  Thus, continuous-duty ac oil-type or metalized film capacitors are installed in PSC motors.  The dielectric in the capacitor is an oil-impregnated paper or plastic film as opposed to the aluminum oxide in ac electrolytic capacitors.  The oil-type capacitor is inherently larger and more costly than the metallized film or electrolytic type.</p>
<div id="attachment_236" class="wp-caption alignleft" style="width: 310px"><a href="http://gearmotorblog.files.wordpress.com/2010/01/ac_230-460_pace_group_suqare_lg01_blog.jpg"><img class="size-medium wp-image-236" title="AC Induction Motors and Gearmotors from Bodine" src="http://gearmotorblog.files.wordpress.com/2010/01/ac_230-460_pace_group_suqare_lg01_blog.jpg?w=300&#038;h=277" alt="AC Induction Motors and Gearmotors from Bodine" width="300" height="277" /></a><p class="wp-caption-text">AC (Fixed Speed) Induction Motors and Gearmotors from Bodine</p></div>
<p>The PSC motor operates similarly to a two-phase motor and is, therefore, inherently more quiet and efficient than a CS motor.  However, the phase angle in a PSC motor changes with load so that the motor usually is less efficient during starting than during running.  In usual motor design, a compromise is made between the two operating points.  Changing the capacitor value as specified by the manufacturer will affect both running and starting characteristics so that any improvements in starting usually decrease running performance.  For example, a 200% increase in capacitance in a typical 1/15-hp motor approximately doubles the starting torque.  However, the running efficiency of the motor drops from approximately 50% to 18%, and serious overheating of the motor results. Many motors are designed to operate close to the thermal limit of their insulation class rating. An increase in capacitance can increase the winding temperature rise above the allowed limit.</p>
<p>Some PSC motors use a second capacitor for starting purposes only.  This second capacitor may be an electrolytic or metallized film type.  This version is called a two-capacitor motor or a two-capacitor-start, one-capacitor-run motor.  Two capacitors preserve the efficiency and quietness of the PSC motor when running while improving the starting characteristics.  By using one capacitor for running and another in parallel for starting, starting torque can be increased without impairing running performance.  An analysis of the PSC speed-torque curve reveals that where acceleration is important, it would be wise not to use too large a capacitance for starting purposes.  In fact, even though the starting torque may be the same for two values of capacitance, the average accelerating torque may be less for the larger capacitance.</p>
<p><span style="text-decoration:underline;">Supporting Images and Charts:</span></p>
<p>1) How to read a Speed-Torque Curve (Bodine Handbook, page 7-25)</p>
<p><a href="http://gearmotorblog.files.wordpress.com/2010/01/read-ac-speed-torque-graph_handbook_blog.jpg"><img class="aligncenter size-full wp-image-266" title="Read-AC-Speed-Torque-Graph_Handbook_Blog" src="http://gearmotorblog.files.wordpress.com/2010/01/read-ac-speed-torque-graph_handbook_blog.jpg?w=500&#038;h=229" alt="" width="500" height="229" /></a><a href="http://gearmotorblog.files.wordpress.com/2010/01/read-ac-speed-torque-graph_handbook_blog.jpg"></a></p>
<p>2)  Bodine Type 42R5”CI” AC Motor Example with various Capacitors</p>
<p><a href="http://gearmotorblog.files.wordpress.com/2010/01/capacitor-motor_graph_01-25-2010.jpg"><img class="aligncenter size-full wp-image-265" title="Bodine Type 42R5”CI” AC Motor Example with various Capacitors" src="http://gearmotorblog.files.wordpress.com/2010/01/capacitor-motor_graph_01-25-2010.jpg?w=500&#038;h=333" alt="Bodine Type 42R5”CI” AC Motor Example with various Capacitors" width="500" height="333" /></a></p>
<p>1 &#8211; Rated Speed and torque (approx. 98 oz-in at 1700 RPM, 4-pole) 2 &#8211; Breakdown Torque   3 &#8211; Starting Torque</p>
<h3>Comments to above graph:</h3>
<p> A) Changing the factory specified capacitor to a different than rated value will void the product warranty, may affect motor performance, and/or can lead to product failure.</p>
<p>B) The above graph is an example only! The gains shown may or may not apply to any  Bodine AC, PSC stock windings. Motor heating, insulation class limits, and current draw must be reviewed on a case-by-case basis!</p>
<ul>
<li>
<div style="text-align:left;">the synchronous speed of a 4-pole AC motor at 60Hz is 1800 RPM</div>
</li>
<li>
<div style="text-align:left;">this particular winding example has slightly more starting torque than running torque</div>
</li>
<li>
<div style="text-align:left;">effects from capacitor change vary from frame to frame, and winding to winding</div>
</li>
<li>
<div style="text-align:left;">increased capacitance (&gt;100%) will increase current draw and power consumption</div>
</li>
<li>
<div style="text-align:left;">the motor’s duty cycle will have to be reduced if capacitance is chosen too high</div>
</li>
<li>
<div style="text-align:left;">increased current draw from a larger capacitor might cause fuses or breakers to go off/trip</div>
</li>
<li>
<div style="text-align:left;">capacitor changes will affect the motor’s power factor/phase angle, which in turn, will affect current draw, power and heat…</div>
</li>
</ul>
<p style="text-align:left;"><a title="Bodine Tech Article on Capacitor Motors" href="http://gearmotorblog.files.wordpress.com/2010/01/bodinetechinfo_hotrodding-ac-capacitor-motors_01-2010.pdf" target="_blank">Click here</a>, to download a PDF version of this article.</p>
<p>By Edmund Glueck.  Copyright  <a title="Bodine AC Gearmotors and Motors" href="http://www.bodine-electric.com/Asp/ProductMenu.asp" target="_blank">Bodine Electric Company </a>©  01/2010.  All rights reserved.</p>
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