I'm trying to reduce a PSC electro-motor rpm to about 80% to 90% of it's nominal speed. It is attached directly to a centrifugal fan and a mechanical approach is not possible. The ratings are: 450 W, 2.2 A , 220 VAC, 50 Hz, 700 rpm, winding insulation class B.
I tried placing a series 15 Ω 150 W resistance on the current path. And it worked fine but the resistance got too hot, adding a heat sink helped but didn't completely solved the problem.
I also tried using a dimmer circuit, and it caused a 15 degree Celsius temperature rise from the normal temperature (I think because of the added harmonics), which is 60 degrees in 23 degree environment (all skin temperature). Since the working environment of this fan is 45 degree Celsius and the insulation class is B, I think dimmer solution would fail.
I'm now thinking about placing a series inductance on the current path. But I haven't seen a single page about this approach on the internet and I don't know if this would work. Inductor in this size is not readily available and making it is a lot of work. I would like to know why this approach may not work.
I would also appreciate any other solution or idea which cost less than 10 to 20$.
Best Answer
A motor with class B insulation should be able to withstand 80C rise by resistance in a 40C ambient. That would be 75C in a 45C ambient. It is difficult to estimate what the rise in skin temperature would need to be would need to be.
A series inductor should work similarly to a series resistor except that the phase angle of the voltage drop will be nearly 90 degrees with respect to the supply voltage. As a result, 150 ohms inductive impedance will not provide the same motor voltage as was provided using the resistor. If you measure the voltages across the 150 ohm resistor and across the motor, you should be able to calculate the inductance needed for an equivalent result.
Reducing the speed of the motor by reducing the voltage will increase the motor slip. That will increase the rotor losses, but the reduction in load gained by reducing the fan speed compensates for that. However if the motor is overloaded when running the fan at the rated motor speed, the motor could still overheat at the reduced speed.
Another alternative that you might consider is to reduce the capacitance of the auxiliary winding capacitor. The value will need to be determined by trial and error.