Basic Motor Technical + Safe Area Motors

Chiam Chee Seong
BU Motors and Generators
Basic Motor Technical & Non-Hazardous Area Motors Portfolio

ABB BU Motors and Generators December 23, 2013 | Slide 1
BU Motors and Generators Key facts and Figures

Worlds leading manufacturer of LV, MV and HV motors and generators, and mechanical power transmission products serving all industries and applications, on all markets >2400 employees in 41 countries 5 focused manufacturing centers Complete product offering from subfractional HP up to 70 MW
LV, MV and HV induction motors and generators Synchronous and permanent magnet motors and generators DC motors, servomotors, gear motors Mechanical power transmission products
5 central stocks, 60 000 stocked motors
BU Motors and Generators Unmatched ability to serve global and local customers
Total offering NEMA LV IEC LV Motors Large < Large > Gear Small generators Generators Large generators Gen sets Mechanical power transmission Service
ABB
Baldor
ABB + Baldor
11000 kW 15000 hp 11000 kW 15000 hp
Component Parts of a Motor

Fan cover
Terminal cover Terminal box Stator core
Terminal block
Fan N-End-shield+bearing
D-End-shield+bearing Stator house Rotor Shaft Stator winding
The Making Process
Punching
Stator manufacturing
Rotor casting
Rotor assembly
Winding
Coupling
Stitching Impregnation
Testing
Packing
Assembly
Insulation
In a LVAC electrical motor there are Wire insulation (Enamel Insulation)
Slot insulation
Insulation (Cont.)
Slot cover or slot wedge
Phase insulation
Insulation (Cont.)
Layer insulation
Tying or lacing band
Impregnation
Trickle impregnation (applied on frame 280 and above)

Heating during rolling: 20C/min, temperature in the end of the rolling 130 - 140C (epoxy 160C)
Stoving: Temperature of the stove 150oC, stoving time 50 min
Impregnation
Vacuum impregnation (applied on frame below 280)

Vacuum sucks the resin into winding Impregnation time 45 min No heating during impregnation
Stoving: Temperature of the stove 140oC, stoving time 4 h
IEC Motor Mechanical Design

Frame Construction Modern totally enclosed squirrel cage motors are available in a choice of aluminum, steel and cast iron frames for different application areas. Available frame materials for ABB motors are cast iron and aluminium. Frame Size - The height of shaft center point in relation to the surface of the ground (typically measured in mm). - Common IEC frame sizes for LV motors are 56, 63, 71, 80, 90, 100, 112, 132, 160, 180, 200, 225, 250, 280, 315, 355, 400 and 450.
Mounting Arrangements
-
There are Code I and Code II for motor mounting arrangements. Marked *) means its not specified in IEC 60034-7. Mounting arrangement is very important to manufacturer as there might have some special consideration required especially for vertical mounted motors (eg: V3, V6, V1.) Special end shield or seals is required for those shaft upwards where water/liquid are expected to go down along the shaft.
Cooling and Degree of Protection (IP/IK)
Terminal Boxes
Bearings
-
ABBs LV motors are provided with deep groove ball bearings as standard. The complete bearing designation is stated on rating plate of most motor types. Bearing selection is based on forces from load towards to bearings (eg: axial force, radial force and thrust force). Its advisable to provide the force value, mounting , direction and magnitude to ABB for precise verification. Common bearing selection on applications below:Roller bearing High radial force (eg: belt, conveyor) Angular contact bearing High thrust force (eg: vertical mounted..) The normal life L10 of a bearing is defined, according to ISO, as the number of operating hours achieved or exceeded by 90 per cent of identical bearings in a large test series under certain specific conditions. 50 per cent of the bearings achieve at least five times this figure. Insulated bearing is needed for VSD motors, please refer to VSD section for more information.
Enclosure Surface Treatment and Colour
All the painting system are according to ISO/EN 12944 standard. ISO/EN 12944 divides durability into 3 categories: Low (L), Medium (M), and High (H) where Low (L) durability corresponds to 2-5 years, Medium (M) 5-15 years and High (H) more than 15 years. All the ABB motors are treated with Medium (C3M) surface treatment and Munsell Blue 8B 4.5/3.25 paint colour as standard. Others painting systems are available upon request.
Vibration
-
Vibration according to Grade A is applied to ABB motors as standard. The vibration measurement is performed for all motors and generators according to IEC 60034-14. Grade B vibration level is available upon request.
Low voltage Non-hazardous Area Induction Motors (Comparison)
VS
Process Performance Tailor-made IE2, IE3 & IE4 efficiencies Wide variant feasibility Longer warranty period More demanding VSD applications General Performance Off-the-shelf Only IE2 efficiency Limited optional variant codes Shorter warranty period Simple quadratic loads
Process Performance Motors

Low voltage Process Performance Motors

Motors for the most demanding continuous process applications Tailor-made to meet the individual needs of applications Prepared to answer any reliability, availability and energy efficiency challenge, both now and in the future
Process Performance Motors Range

Sizes 71-450
56 63 71 80 90 100 112 132 160 180 200 225 250 280 315 355 400 450
Process performance motors

56 63 71 80 90 100 112 132 160 180 200 225 250 280 315 355 400 450 IE2 High efficiency aluminum motors (M3AA)
IE2 High efficiency cast iron motors (M3BP)
IE3 Premium efficiency motors M3BP (Aluminum M3AA <250) IE4 Super premium efficiency motors M3BP
Process Performance Motors High efficiency motors

Motors for the most demanding continuous process applications Tailor-made to meet the individual needs of applications Fulfilling IE2 efficiency class, available from stock* 3 years warranty, option for 5 years Output 0.25 kW to 1 MW Type M3BP Frame sizes 71 to 450 Cast iron Output 0.12 kW to 90 kW Type M3AA Frame sizes 63 to 280 Aluminum
Process Performance Premium Efficiency Motors

Motors for the most demanding continuous process applications Tailor-made to meet the individual needs of applications Fulfilling IE3 efficiency class, available from stock* Output 11 to 375 kW Type M3BP Frame sizes 160 to 355 Cast iron Output 7.5 kW to 55 kW Type M3AA Frame sizes 160 to 250 Aluminum
Process Performance Super Premium Efficiency Motors

Motors for the most demanding continuous process applications Tailor-made to meet the individual needs of applications Fulfilling IE4 efficiency class Continuous development for future needs of efficiency Output 75 to 375 kW Type M3BP Frame sizes 280 to 355 Cast iron
General Performance Motors

General Performance Motors Range
A limited number of options available Only available from stock Efficiency class IE2 Shorter delivery time Only the D- and S-voltage codes are available
ABB /BU Motors and Generators December 23, 2013 | Slide 28
General Performance Motors High Efficiency Motors

General Performance IE2 high efficiency cast iron & aluminum motors, suited for applications where simplicity and off-the-shelf availability are paramount. With ABB quality and support, these motors have the features appreciated by volume customers and serial OEMs. Fulfilling IE2 efficiency class, available from stock Output Type Frame sizes Output Type Frame sizes 0,18 kW to 355 kW M2BA 71 to 355 cast iron 0.06 kW to 55 kW M2AA 56 to 250 Aluminum
Basic Information for Dimensioning (DOL)
Supply: Voltage, frequency, and its variation Load: Torque vs Speed curve, application, speed Environment: Safe/Ex, ambient temperature, altitude Standard/ specification: IEC/NEMA, Marine, and etc. Additional requirements: Mounting, cooling, IP rating.
Terminology - Basic Formulas
Permissible Temperature Rise
Torque vs Speed Curve
Starting Type
BU Motors and Generators VSD Motors

65% of electricity used in industry is absorbed by electrical motors 20% of this energy is dissipated by losses of electrical motors The use of best technology (including high efficiency motors, use of drives etc.) would lead to a reduction of emission of CO2 by 68% from 23,500 Mton/year down to 7,500Mton/year
BU Motors and Generators Major Benefit of using VFD

PERFORMANCE CONTROL
AC drives are used to bring process and quality improvements in industrial applications through drives' control superiority in terms of key parameters including acceleration, flow, monitoring, pressure, speed, temperature, tension and torque. Energy Saving AC motor-driven applications that do not require full speed can save energy by controlling the motor with a variable speed drive. Energy cost saving with variable torque can be significant, often paying for the cost of VFD within a matter of months for some specific applications(e.g. variable speed fan, pump).
Made in ABB VSD motor characteristics - Comparison with constant speed motor
Constant speed motors
VSD motors (Advantage) Current will be well controlled around nominal current, and hence much less impact to the network. No extra attention needed for the thermal stress during starting, and no limitation on number of consecutive starts due to thermal problem. Starting torque is close to maximum torque, making start easy
Starting current surge up to more than 8 times nominal current, and hence a big voltage drop on network. Sometimes this phenomena might cause motor starting failure or network black out Consideration of the heating during start is inevitable, and hence a limited number of consecutive starts. Starting torque could be a problem sometimes for high load torque and high inertia application
VSD motor characteristics - Comparison with constant speed motor

Constant speed motors
VSD motors (Extra Consideration) Having an operating range (speed and power), hence, sizing is made to the whole range, including the relationship between critical speed and the operating speed range, and the need to enhance the cooling at low speed range. Extra insulation might be needed due to voltage peak Extra insulation needed for bearing because of the shaft voltage caused by the inherent association with high frequency voltage Might cause higher noise level hence might need to consider noise control
Having only one operating point (speed and power), hence, sizing is made only to that one point. Sinusoidal input, no extra heating due to harmonic distortion. Sinusoidal input, no extra insulation requirements due to voltage peaks. Sinusoidal input, no extra insulation for bearing needed. Sinusoidal input, noise level relatively low
More Information for VSD Motors

What is the load type/ application? What is the operating speed range? What is the VSD power required? Is there any overload condition? If yes, what is the duration? Which drive to be used?
Process performance motors VSD - Loadability curves

Based on comprehensive tests With separate cooling full 100% loadability possible also at low speeds The curve shows loadability of process performance motor on converter duty as a relation to nominal torque This loadability curves represent only the thermal loadability. Other factors may also limit the loadability (i.e. the max. Allowed speed of the motor)
ACS800/50 Hz, temp rise B
Process performance motors VSD - Loadability curves, ACS 800
ACS800/50 Hz, temp rise F
Process performance motors VSD - Loadability curves, ACS 550
ACS550/50 Hz, temp rise F
Process performance motors VSD Insulation and filtering

Nominal supply voltage UN of the converter UN 500 V UN 600 V Winding insulation and filters required ABB Standard insulation ABB Standard insulations with du/dt-filters at converter output OR ABB Special insulation (variant code 405) ABB Special insulation (variant code 405) AND UN 690 V AND cable length > 150 m du/dt-filters at converter output ABB Special insulation (variant code 405)
UN
690 V
What will Happen if Incorrect Winding Insulation Applied for Continuous VSD Application?
Insulated Bearing on VSD Driven Motor

Common mode voltages of voltage source of converters are causing high frequency bearing currents
IN V E R T E R 2 1 M O TOR C ABLE MOTOR GEAR LO A D
4 7
C o m m on m od e v o ltag e p u ls e
-D C
+D C
H ig h fre q u en c y com mon m ode c u rre n t
H ig h fre q ue n c y sh a ft v o ltag e
H ig h fre q ue n c y circ u la tin g c u rre n t
1 3 P E -cu rren t 6 H ig h fre qu e n c y fra m e v o ltag e 7 S h aft g ro u n d in g cu rre n t
Insulated Bearings and Filters

Use of non-suitable bearings, the surfaces of rolling elements and raceways in the bearing might be damaged and degrade the grease rapidly (electric erosion). This is all due to common shaft current from converter supply. Bearing voltages and currents must be avoided with insulated bearings (VC+701) and/or properly dimensioned filters at the converter must be used as shown in guideline table below:Nominal power PN and/or IEC frame size PN < 100 kW PN 100 kW OR IEC 315 Frame size PN 350 kW OR IEC 400 Frame size Preventive measures No actions needed Insulated non-drive end bearing (VC+701) IEC 355 Insulated non-drive end bearing (VC+701) AND Common mode filter at the converter
IEC 450
Process performance motors VSD Insulated bearing

Bearing currents in VSD duty can damage the surfaces of rolling elements and raceways in the bearing and degrade the grease rapidly (electric erosion) Insulated bearing eliminates the bearing currents Longer bearing lifetime less maintenance Several hundred of tests at site show that it is only needed on N-end Outer ring plasma spray coated and further treated to make it insensitive to moisture and humidity Only high quality insulated bearings are used
Sample Damages of Shaft Current to Conventional Bearings
Multiple Choice of Variants (Process Performance)
Process performance motors Documentation

Support Knowledge and expertise Stock Options, variant codes Traceability Documentation After sales
Available from web sites in ABB standard format EC declarations of conformity Dimensional drawings 2D and 3D CAD drawings Connection diagrams (Basic) O & M Manual Available on request: Data sheet Performance curves incl. torque-speed curves Routine test certificates Environmental certificates Noise spectrums Type test reports Test together with frequency converters
High Efficiency Motors

65 % of total electricity at industrial sites is consumed by electric motors Motor purchasing price corresponds to 8 to 12 weeks of its electricity consumption The capital cost will represent only 1% of the total life cycle operational costs of the motor Reliable motors with a high efficiency level ensure the lowest life cycle costs
Energy Efficiency and Carbon Footprint Reduction Energy facts about LV motors
78.8 kW 81.4 kW
Loss 3.8 kW
Efficiency = 95.1 % Reduced losses = 2.6 kW
75 kW
Loss 6.4 kW
Efficiency = 92.1 %
If the efficiency level increases with 3 %-units, the reduction of losses is 40%
Annual savings = 2.6 kW x 0.055 EUR x 8760 hrs = 1251 EUR / 11 tonnes CO2 (0.5 kg/kwh)
New efficiency classes defined by IEC/EN 60034-30
Super premium efficiency * High efficiency
IE4
Super premium efficiency Premium Comparable to EFF1 Comparable to EFF2
Premium efficiency IE3 IE2
Standard efficiency IE1
*) IE4 level for asynchronous and synchronous motors defined by IEC 60034-31: 2010 Technical specification
New efficiency classes defined by IEC/EN 60034-30 and IEC/TS 60034-31

Note! IE4 level for asynchronous and synchronous motors defined by IEC 6003431: 2010 Technical specification
Timelime for the EU MEPS
Note! IE classes required by the regulation correspond to IE class defined in IEC/EN 60034-30 standard
Phase 1: From 16 June, 2011
Motors with specification below must meet the IE2 efficiency level:0.75kW-375kW, 2-6 poles, up to 1kV 50Hz
Phase 2: From 1 January, 2015 Phase 3: From 1 January, 2017
Motors with a rated output of 7.5 375 kW must meet EITHER the IE3 efficiency level OR the IE2 level if fitted with a variable speed drive Motors with a rated output 0.75 375 kW must meet EITHER the IE3 efficiency level OR the IE2 level if fitted with a variable speed drive
IEC/EN 60034-30: 2008 and other efficiency standards Rough comparison

IEC/EN 60034-30 EU MEPS CEMEP (European voluntary agreement) US EPAct Other, similar local regulations
IE3 Premium efficiency
IE3 Premium efficiency IE2 High efficiency
Identical to NEMA Premium efficiency

Canada Mexico Australia New Zealand Brazil 2009 China 2011 Switzerland 2012 China Brazil Costa Rica Israel Taiwan Switzerland 2010
IE2 High efficiency
Comparable to EFF1 Identical to NEMA Energy efficiency /EPACT
IE1 Standard efficiency
Comparable to EFF2 Below standard efficiency
Process performance cast iron motors Structure - Rating plate, more examples for different motor sizes
Motor sizes 71-90
Motor sizes 100-132
Motor sizes 160-250
BU Motors and Generators LV Motor Manufacturing and Central Stock Locations

Vsters, Sweden Vsters, Sweden Central Stock North Menden, Germany Central Stock Europe Vaasa, Finland
Shanghai, China Shanghai, Central Stock North Asia
Barcelona, Spain Central Stock South
Singapore, Central Stock South Asia
Manufacturing Central stocks
Lodz, Poland
Faridabad & Bangalore, India
Manufacturing / PG IEC Large and Ex motors FIMOT - ABB Oy, Motors in Finland, Vaasa
Personnel 505 (2009) 450 km from Helsinki Visiting address: Strmbergin Puistotie 5 A, FI-65320 Vaasa Factory area 34.000 m2 Focus and R&D responsibility: Motors for frame sizes 71-132 & 280450, cast iron safe area motors Hazardous area motors for frame sizes 71 to 450
Manufacturing / PG IEC Medium motors
SEMOT - ABB AB, LV Motors in Vsters, Sweden

Personnel 230 (2009) 100 km from Stockholm Visiting address: rjansgrnd 10, SE-72170, Vsters Focus and R&D responsibility: Safe area cast iron motors for frame sizes 160 to 250 Safe area aluminium motors for frame up to 280
Manufacturing CNMOT ABB Shanghai, China

Personnel 600 (August 2007) Visiting address: 88, Tianning Road, Minhang (Economical & Technological Development Zone) Shanghai, 200245, P.R. China Production: Cast iron motors for frame sizes 71 to 400
Manufacturing PLABB - Poland

Newest motor factory, started production 2009 Visiting address:
Ul. Placydowska 27 95-070 Aleksandrw Ldzki, lzkie Poland Land: 88,502 m2 Buildings: 12,283 m2 Infrastructure: 77,318 m2
Manufacturing INABB Faridabad and Bangalore, India

Faribadad Visiting address:
32 Industrial Area, NIT, Faridabad, Haryana - 121001
Personnel: 214 (2009) Production:

Cast iron motors for frame sizes 71 to 250
Bangalore Visiting address:

Plot no 5 & 6, Peenya industrial area, Phase 2, Karnataka-560058
Personnel: 1400 Production:

Cast iron motors for frame sizes 280 to 400
LV Motors Logistics
Central Stocks strategically located around the world One common Order Management System (single data entry) Online access and support (EDI and www) Delivery within 2-72 hours, modifications in 24 hours
Central Stock Europe Menden, Germany

Visiting address:
Brukerweg 132, 58708 Menden, Germany
Central stock of motors for the Central European market M2: 11,000 2,000 different motor types in stock 185 modified motors per day 1,150 delivered motors per day 200 shipments per day
Central Stock North Vsters, Sweden

Visiting address:
rjansgrnd 1 721 32 Vsters
Central stock of motors for the North European market M2: 9,600 1,200 different motor types in stock 150 modified motors per day 870 delivered motors per day 150 shipments per day
Central Stock South Sabadell, Spain

Visiting address:
CL Illa de Buda, 55 - P.I.Sur-Oeste, 08192, Sant Quirze del Valles, Spain
Central stock of motors for the South European market M2: 2,300 1,000 different motor types in stock 75 modified motors per day 1,040 delivered motors per day 45 shipments per day
Central Stock North Asia Shanghai, China

Visiting address:
Minhang Economic & Tech.Dev Zone, Tianning Rd.#88 Sanghai, 200245, P.R.China
Central stock of motors for the North Asian market
M2: 5,000m2 1,200 different motor types in stock 1,200 delivered motors per day 50 shipments per day
Central Stock South Asia Singapore

Visiting address:
2 Ayer Rajah Crescent, Singapore 139935, Singapore
Central stock of motors for the South Asian market
M2: 1,200 200 different motor types in stock 10 modified motors per day 100 delivered motors per day 2 consolidated shipments per day
MV/HV Machines Product Platforms
100000 10000
AMI Vittuone Vsters AML AMD Traction M3 HXR AMA AMK Vsters
AMZ AMG
1000
DMI
Hki, Vittuone, Shanghai
AMZ Azipods Helsinki
kW : motor application, kVA : generator application
AMC
AMT AMS
AMG
Vittoune, Alrode
Vittuone
100
Hki, Shanghai Hki, Shanghai United States Vsters
DC
TEFC EEx-d SCIM
Modular SCIM / WRIM Induction
AC
4&6 p
>8 p
4,6,8,10 p
Synchronous
Nanchang
10
Shanghai
Vittuone
Helsinki
ABB the first to use the IECEx conformity mark

ABB is the first motor manufacturer to be granted a licence to use the IECEx conformity mark Globally certified, with global support and certified service
Mechanical Power Transmission Products For Motor-Driven Loads

Mounted bearings Ball bearings Roller bearings Plain bearings Enclosed gearing Helical gear Worm gear Shaft Mount PT Components Bushings / sheaves Conveyor pulleys Couplings / brakes
Process performance motors After sales

Support Knowledge and expertise Stock Options, variant codes Traceability Documentation After sales
Invitably, at some point in the lifecycle of an electric motor our customers will need additional support from us We have the infrastructure to offer the specific support the customer needs either via our own workshops or by our certified workshops around the world Onsite problem solving
Global Service Products Local Service Centers
Some Customer Segments
Chemical & Petrochemical
Water & waste water
Metals & mining
Oil & Gas
Food & Beverage
Pulp & paper
Steel
Cranes & Marine
Rail

Basic Motor Technical + Safe Area Motors

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Basic Motor Technical + Safe Area Motors

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Chiam Chee Seong

BU Motors and Generators

Basic Motor Technical & Non-Hazardous Area Motors Portfolio

BU Motors and Generators Key facts and Figures

5 central stocks, 60 000 stocked motors

ABB BU Motors and Generators December 23, 2013 | Slide 2

11000 kW 15000 hp 11000 kW 15000 hp

Component Parts of a Motor

Terminal cover Terminal box Stator core

D-End-shield+bearing Stator house Rotor Shaft Stator winding

ABB BU Motors and Generators December 23, 2013 | Slide 6

The Making Process

ABB BU Motors and Generators December 23, 2013 | Slide 7

ABB BU Motors and Generators December 23, 2013 | Slide 8

ABB BU Motors and Generators December 23, 2013 | Slide 9

Tying or lacing band

ABB BU Motors and Generators December 23, 2013 | Slide 10

Trickle impregnation (applied on frame 280 and above)

Stoving: Temperature of the stove 150oC, stoving time 50 min

ABB BU Motors and Generators December 23, 2013 | Slide 11

Vacuum impregnation (applied on frame below 280)

Stoving: Temperature of the stove 140oC, stoving time 4 h

ABB BU Motors and Generators December 23, 2013 | Slide 12

IEC Motor Mechanical Design

ABB BU Motors and Generators December 23, 2013 | Slide 13

ABB BU Motors and Generators December 23, 2013 | Slide 14

Cooling and Degree of Protection (IP/IK)

ABB BU Motors and Generators December 23, 2013 | Slide 15

ABB BU Motors and Generators December 23, 2013 | Slide 16

ABB BU Motors and Generators December 23, 2013 | Slide 17

Enclosure Surface Treatment and Colour

ABB BU Motors and Generators December 23, 2013 | Slide 18

ABB BU Motors and Generators December 23, 2013 | Slide 19

Low voltage Non-hazardous Area Induction Motors (Comparison)

ABB BU Motors and Generators December 23, 2013 | Slide 20

Process Performance Motors

Low voltage Process Performance Motors

ABB BU Motors and Generators December 23, 2013 | Slide 22

Process Performance Motors Range

Process performance motors

IE2 High efficiency cast iron motors (M3BP)

ABB BU Motors and Generators December 23, 2013 | Slide 23

Process Performance Motors High efficiency motors

Process Performance Premium Efficiency Motors

Process Performance Super Premium Efficiency Motors

ABB BU Motors and Generators December 23, 2013 | Slide 26

General Performance Motors

General Performance Motors Range

General Performance Motors High Efficiency Motors

ABB BU Motors and Generators December 23, 2013 | Slide 29

Basic Information for Dimensioning (DOL)

Terminology - Basic Formulas

ABB BU Motors and Generators December 23, 2013 | Slide 31

Permissible Temperature Rise

ABB BU Motors and Generators December 23, 2013 | Slide 32

Torque vs Speed Curve

ABB BU Motors and Generators December 23, 2013 | Slide 33

ABB BU Motors and Generators December 23, 2013 | Slide 34

BU Motors and Generators VSD Motors

ABB BU Motors and Generators December 23, 2013 | Slide 35

BU Motors and Generators Major Benefit of using VFD

ABB BU Motors and Generators December 23, 2013 | Slide 36

ABB BU Motors and Generators December 23, 2013 | Slide 37