Electric Motors: Functioning, Components, Frame Size, Enclosure, Mounting & Operations

Providing an exploration into the basics of electric motors, this article focuses on nomenclature, term definitions, components, frames, enclosures, and common motor styles. After reading this article, you will have a broad understanding of what motors are, and how to identify their many components.

People and animals were the original power generation units. Animals pulled carts, turned grain mills, and pulled water from wells. Consequently, humans did the chores animals couldn’t do. However, both forms of physical labor were undependable due to lack of funds, disease, and injury. Ancient inventors realized there was a way to do more work and exert less physical input. Thus, the search for a dependable power source was on.

The waterwheel changed the way factories provided energy to their fabrication equipment. Simple in operation, the waterwheel received its power from a running body of water, usually a river or waterfall. The flow of water turned the waterwheel, producing energy. The waterwheel’s energy rotated a large mainline drive shaft that ran through the middle of the building. Individual machines were linked to the main drive shaft via leather belts that transmitted rotational energy

Unlike waterwheels and windmills, the steam engine was not dependent upon a natural source. Therefore, steam engines could be located anywhere. The steam engine proved to be a dependable source of power; however, there was still a need for a less complex, smaller, efficient, and versatile power source to keep up with other technological advances.

  • Frame – The frame is a housing that holds all internal and external motor components.
  • External Fan – Positioned on the exterior end of the motor assembly, the fan blows air across the outside of the motor to prevent overheating.
  • Fan Cover – Protects the fan from foreign object damage and protects people from injury.
  • Cast Rotor – Also known as the armature. The armature is the assembly of windings. These windings interact with the stator to form the magnetic fields necessary for generating rotation energy.
  • Stator Stationary portion of the motor’s electrical field.
  • Front Bearing – Shaft support that reduces friction rotation. The front bearing is located at the end where the shaft extends from the motor housing.
  • Rear Bearing – Shaft support that reduces friction rotation. The rear bearing is located at the same end as the external cooling fan.
  • Base – Also referred to as the foot mount, the base secures the motor housing to the equipment platform.
  • Shaft – The shaft runs longitudinally through the center of the stator, and is supported by the front and rear bearings.
  • Capacitor – Affixed to the outside of the motor, the capacitor shifts the phase of the incoming current and feeds the starter winding.
  • Front End Shield – Located at the end where the shaft extends from the motor, the front end shield encloses the motor frame and supports the front bearing.
  • Rear End Shield – Located at the same end as the external cooling fan, the rear end shield encloses the motor frame and supports the rear bearing.
  • Internal Fan – Located within the motor housing, the internal fan circulates air internally
  • Nameplate – A tag affixed to the motor to designate motor specification parameters.
  • Connection Box – A box affixed to the motor housing where motor connections are made with the power supply.
  • End Ring – Located at the end of the rotor assembly, the end rings provide a surface to connect the rotor bars.
Components of AC electric motor Single Phase
  • Horsepower (HP) – Horsepower is the power the motor is capable of putting out continuously.
  • Phase (Ph) – Phase data indicate[s] whether the motor is a single or Polyphase machine.
  • Hertz (Hz) – Hertz is the frequency of the electrical source. In the United States and Canada, this frequency is 60Hz or cycles per second. In other parts of the world 50Hz is the standard. Because US and Canadian manufacturers import specialized equipment internationally, US motor manufacturers produce 50Hz motors for aftermarket sales purposes.
  • Frame Size (Frame) – Frame size is a number that defines the physical dimensions of the motor (see section 0).
  • Voltage (Volts) – Voltage is the voltage rating at the motor terminals. Usually satisfactory operation can be expected at a 10 percent variation from the indicated voltage.
  • Full Load Current (Amps) – Full load current (amps) is the current draw of the motor connected to the nameplate voltage, loaded at nameplate horsepower and running at nameplate speed. Design Letter (Design) – The NEMA/CEMA design letter governs motor torque and slip characteristics. Design letter definitions can be found in section 0 below.
  • Letter Code (Code) – The letter code applies to starting conditions in kilovolts/amps per horsepower (kVA/HP) when starting the motor on full voltage.
  • Service Factor (SF) – The service factor indicates the ability of the motor to deliver more than nameplate horsepower. To arrive at the increased rating, multiply the nameplate horsepower by the service factor. The same also applies to the current. With the exception of 1 HP, 3600 revolutions per minute (which have a service factor of 1.25), all standard NEMA general-purpose drip-proof integral horsepower T-frame motors through 200 HP have a service factor of 1.15. T-frame motors above 200 HP, and totally enclosed T-frames have a service factor of 1.0.
  • Speed (RPM) – Speed is the speed at which the motor rotor shaft will rotate when loaded with the nameplate horsepower.
  • C – NEMA – The NEMA C face mount is a machined face with a pilot on the shaft end that allows direct mounting with the pump or other direct coupled equipment. Bolts pass through the mounted part to a threaded hole in the motor face. It is possible to specify a C-face configuration with or without a rigid base.
  • D – NEMA – NEMA D Flange Mount is a machined flange with a rabbet for mountings. Bolts pass through the motor flange to a threaded hole in the mounted part. NEMA C face motors are by far the most popular and readily available. D flange mounting can be specified with or without a rigid base.
  • H – Indicates a frame with a rigid base that has an F dimension larger than that of the same frame without the suffix H. For example, combination 56H base motors have mounting holes for NEMA 56 and NEMA 143-5T, and a standard NEMA 56 shaft.
  • J – J is a NEMA C face configuration, threaded shaft pump motor.
  • JM – Close-coupled pump motor with special dimensions and bearings.
  • JP – Close-coupled pump motor with special dimensions and bearings.
  • M – 63¼4” flange (oil burner).
  • N – 71¼4” flange (oil burner).
  • T & TS – T and TS are integral horsepower NEMA standard shaft dimensions if no additional letters follow the T or TS.
  • Y – Non-NEMA standard mount; a drawing is required to be sure of the dimensions. Can indicate a special base, face, or flange.
  • Z – Non-NEMA standard shaft; a drawing is required to be sure of the dimensions.
NEMA Frame and Shaft Size of AC Electric Motors
  • Splash-Proof – A splash-proof motor is an open machine in which the ventilating openings are so contracted that successful operation is not interfered with when drops of liquid or solid particles strike or enter the enclosure at any angle.
  • Semi-Guarded – A semi-guarded motor is an open machine in which part of the ventilating openings in the motor, usually in the top half are guarded as in the case of a “guarded machine” but the others are left open.
  • Guarded – A guarded motor is an open machine in which all openings give direct access to live metal or rotation parts.
  • Drip-Proof Fully Guarded – A drip-proof fully guarded motor is a drip-proof machine whose ventilating openings are guarded in accordance with the requirement of a guarded machine.
  • Open Pipe-Ventilated – An open pipe-ventilated motor is an open machine except that the admission of the ventilating air is so arranged that inlet ducts or pipes can be connected to them.
  • Open Externally Ventilated – Also known as a “force ventilated,” is an open externally ventilated machine that is ventilated by means of a separate motor-driven blower mounted on the machine enclosure.
  • Totally Enclosed Non-ventilated – TENV motors do not have vent openings. They are tightly enclosed to prevent the free exchange of air, but they are not airtight. TENV relies on convection for cooling, as they do not have cooling fans. They are suitable for use where they may be exposed to dirt or dampness, but not hazardous locations or applications with frequent wash downs.
  • Totally Enclosed Fan Cooled – TEFC motors are similar to the TENV except they have an external fan as an integral part of the motor to provide cooling by blowing air over the outside frame.
  • Explosion Proof – The Explosion Proof meets Under-writers Laboratories or CSA standards for use in the hazardous (explosive) locations shown by the UL/CSA label on the motor. The motor user must specify the class of explosion-proof motor required. Locations are considered hazardous when the atmosphere contains, or may contain gas, vapor, or dust in explosive quantities.

The National Electrical Code (NEC) divides hazardous locations into classes and groups according to the type of explosive agent. The following list has some agents of each classification. For a complete list, refer to Article 500 of the National Electrical Code.

  • Group A (Acetylene)
  • Group B (Butadiene, ethylene oxide, hydrogen, propylene oxide)
  • Group C (Acetaldehyde, cyclopropane, diethyl ether, ethylene, isoprene)
  • Group D (Acetone, acrylonitrile, ammonia, benzene, butane, ethylene dichloride, gasoline, hexane, methane, methanol, naphtha, propane, propylene, styrene, toluene, vinyl acetate, vinyl chloride, xylene)
  • Group E (Aluminum, Magnesium, and other metal dusts with similar characteristics)
  • Group F (Carbon Black, Core, or Coal Dust)
  • Group G (Flour, Starch, or Gain Dust
  • Hostile & Severe – Totally Enclosed Hostile and Severe Environment motors are designed for use in extremely moist or chemical environments, but not for hazardous locations.
  • Dust Ignition Proof – A Dust Ignition Proof motor is a totally enclosed machine whose enclosure is designed and constructed to exclude ignitable amounts of dust or amounts that might affect performance or rating. It also does not permit arcs.
  • Waterproof – A waterproof motor is a totally enclosed machine so constructed that it will exclude water applied in the form of a stream from a hose, except that leakage may occur around the shaft provided is prevented from entering the coil reservoir, and provision is made for automatically draining the machine.
  • Totally Enclosed Pipe-Ventilated – A totally enclosed pipe-ventilated motor is a totally enclosed machine except for openings so arranged that the inlet and outlet ducts or pipes may be connected to them for the admission and discharge of the ventilating air.
  • Totally Enclosed Water-Cooled – A totally enclosed water-cooled motor is a totally enclosed machine that is cooled by circulating water.
  • Totally Enclosed Water-Air-Cooled – A totally enclosed water-air-cooled motor is a totally enclosed machine that is cooled by circulating air, which in turn is cooled by circulating water.
  • Totally Enclosed Air-to-Air-Cooled – A totally enclosed air-to-air-cooled motor is a totally enclosed machine, which is cooled by circulating the internal air through a heat exchanger, which, in turn, is cooled, by circulating external air.
  • Rigid Base – A rigid base is bolted, welded, or cast onto the main frame and allows the motor to be rigidly mounted on equipment.
  • Resilient Base – A resilient base mount has isolation or resilient rings between motor mounting hubs and the base to absorb vibrations and noise. A conductor is embedded in the ring to complete the circuit for grounding purposes.
  • NEMA C Face Mount – The NEMA C face mount is a machined face with a pilot on the shaft end which allows direct mounting with the pump or other direct coupled equipment. Bolts pass through the mounted part to the threaded hole in the motor face.
  • NEMA D Flange Mount – NEMA D Flange Mount is a machined flange with a rabbet for mountings. Bolts pass through the motor flange to a threaded hole in the mounted part. NEMA C face motors are by far the most popular and most readily available. Some manufacturers stock NEMA D flange kits.
  • Type M or N mount – The Type M or N mount has special flanges for direct attachment to the fuel atomizing pump on an oil burner. In recent years, this type of mounting has become widely used on auger drives in poultry feeders.
  • Extended through-bolt motors – Extended through-bolt motors have bolts protruding from the front or rear of the motor by which it is mounted. This is usually used on small direct drive fans or blowers.
  • Flat Belt*                1.33
  • Timing Belt+          0.90
  • Chain Sprocket      0.70
  • Spur Gear              0.75
  • Helical Gear           0.85

Losses in a motor result from the rotation of its movable parts and the flow of electricity through its conductors; these are generally classified as mechanical losses and electrical losses, and all are manifested as heat. [3]

Mechanical power is lost in four ways:

  1. The extra power is needed to overcome bearing friction.
  2. The extra power needed to break away the inertia of the rotor at a standstill.
  3. The extra power is needed to overcome the friction caused by the brush contact on the commutator (DC only).
  4. The extra power is needed for the rotor to overcome the resistance of air.

Electrical power is lost in the conductors of both the field and conductors, generally known as copper losses. Losses caused by the action of the magnetic fields are referred to as iron losses and are given off as heat. [3]

Because all machines have some losses, their efficiencies are never 100%. That is, the output power is never the same as the input power. Usually expressed as a percentage, efficiency is the ratio between output and input power. [3]

With the ever-increasing cost of utility energy and the overall cost-effectiveness of the consumer, motor manufacturers are always attempting to produce motors of premium efficiency. The proof of the premium efficiencies’ effectiveness is found in the utilities’ practice of issuing rebates to users who employ motors that consume less electricity. The logic stems from the utilities’ economic concerns, whereby they conclude it is more economically feasible to conserve

energy than it is to build more power plants. To encourage this conservation effort they reward those conscientious electricity users with rebates. Contact your local power utility

/ municipality for the latest programs, and information on premium efficient motors ratings.

Temperature plays an important role in the efficient running of an electric motor. It is important to remember that when a motor is not running efficiently, more energy is consumed. This consumption relates directly to the total cost of your motor’s operation. It is to your advantage to guarantee proper precautions are taken to ensure your motor is running cool. Contact your motor manufacturer for specifics on the effects of temperature on your electric motor and its application.

Again motors should be stored in a clean dry place. More importantly, the electric motor should be kept in an area where it will not experience severe temperature changes. Extreme temperature changes cause condensation within the motor assembly, which corrode or rust unprotected surfaces. If it is impossible to store the motor under cover, contact your manufacturer for proper protection from the elements and possible insect and rodent infestation.