FACTS & FIGURES M A N U FACT U R I N G P LA N TS

WEG is one of the top 3 electric motor manufacturers in the world. WEG is the
world’s most verticalized motor manufacturer, producing almost every motor
component. In dealing with WEG your company counts on:

QUALITY & TECHNOLOGY PRODUCTS & SERVICE

• 9 modern industrial plants • Diversified product range
• 15,000 highly qualified employees • Vast service network
Industrial Park I
• Extensive R & D activities • Specialised sales and service
• ISO 9000 and ISO 14,000 team in over 1000 countries
quality system • Engineering support (1,500
• Fully certified products engineers at your service)

All this at your service for when you really need it. Industrial Park II T E C H N I C A L F E AT U R E S
PRODUCT RANGE AND BENEFITS MINING MOTORS
FLAMEPROOF MOTORS
BRAKE MOTORS
ALUMINIUM MOTORS
SINGLE-PHASE NEM A56
SINGLE-PHASE CAST IRON Industrial Park III
AIR CONDITIONING MOTORS
APPLIANCE MOTORS
DC MOTORS H LINE
HIGH VOLTAGE MOTORS UP TO 50,000kW
SLIP-RING MOTORS
GENERATORS UP TO 200,000kVA Industrial Park IV
SOFT STARTERS & DRIVES UP TO 4,000kW
FUSES
RELAYS
TRANSF ORMERS
CONTACTORS
MOTORS STARTERS Industrial Park V
WEG motors are sold and serviced by: MASTER LINE

WEG America

www.weg.net
s a l e s @w e g . c o m . a u ( f o r LV M o t o r e n q u i r i e s )
s a l e s . m a q u i n a s @w e g . c o m . a u ( f o r H V M o t o r s e n q u i r i e s )
s a l e s . d r i v e s @w e g . c o m . a u ( f o r D r i v e s e n q u i r i e s )
WEG Europe
WAA001/02.07 AGD022007

WEG Australia Pty Ltd

Head Office Queensland New South Wales South Australia Western Australia Western Australia
(Victoria & Tasmania) WEG Australia Pty Ltd WEG Australia Pty Ltd WEG Australia Pty Ltd WEG Australia Pty Ltd L.E Jarvis & Co QUALITY SYSTEM
3 Dalmore Drive 29 Alexandra Place 512 Victoria Street 5/348 Richmond Road Suite 15/755 Albany H'Way 11 Glassford Road
Scoresby Vic 3179 Australia Murarrie QLD 4172 Wetherill Park NSW 2164 Netley SA 5037 Victoria Park East WA 6101 Kewdale WA 6105
Phone: (03) 9765 4600 Phone: (07) 3890 2095 Phone: (02) 9616 3900 Phone: (08) 8351 9822 Phone: (08) 9262 0455 Phone: (08) 9353 1388 WEG MOTORS ISO 9001

Fax: (03) 9753 2088 Fax: (07) 3890 2096 Fax: (02) 9725 4002 Fax: (08) 8351 9463 Fax: (08) 9262 0456 Fax: (08) 9353 1106
THROUGHOUT E L E C R O N I C C ATA L O G U E P U T S A L L INVERTER R AT E D I N S U LAT I O N
T H E D E TA I L AT Y O U R F I N G E R T I P S
THE WEG
MOTOR RANGE
YOU WILL FIND WEG motors incorporate cutting edge technology in motor insulation for inverter
applications. The high voltage spikes and dV/dt generated by IGBT drives can
T H E S E F E AT U R E S reduce the life of a standard insulation by as much as 75%. WEG’s new insulation
system is capable of withstanding 1,500V peak and 5,200Vus/μs at 5kHz, 14
WHICH SETS
thousand times better if compared to today’s industry standard of 0.14V/μs
WEG ASIDE and 865V. The spike resistant wire, standard in all WEG motors, is the result of
WEG’s extensive research on the effects of
FROM THE drives on electric motors. No doubt that the
OTHERS. benefits of this superior insulation is also
invaluable for applications where power
surges are a constant concern. For more
INVERTER RATED information consult our technical papers.
INSULATION WEG electronic catalogue, available
on CD ROM, is the world’s leading CLASS H
In addition to WEG’s unique spike resistant wire, WEG
HIGH EFFICIENCY motor selection software. This BENEFITS
motors use class H enamel and are impregnated with
excellent, easy to use tool provides  HIGHER CORONA class H epoxy resin. The percentage of retained solids of
LOW NOISE the user with the facility to select and print motor data sheets, dimensional drawings I N C E P T I O N VO LTAG E
a resin-based impregnation is on average 2 to 2.5 times
and performance curves. In addition, the application programme calculates bearing life,  BETTER HEAT TRANSFER
better than that of varnish, the industry standard material.
HIGH TORQUE re-greasing intervals and quantity of grease, as well as start up time.  LONGER LIFE
High voltage motors are VPI impregnated. For superior
The catalogue contains technical data on some 35,000 different motors currently produced results with low voltage random-wound motors the
LOW TEMPERATURE RISE continuous resin flow process is adopted.
by WEG. It covers all world markets, i.e. IEC, SAA, NEMA and other international standards
to which WEG manufacture their motors. The CD also contains the contact details for all
HIGH GRADE CAST THERMAL
WEG branches, representatives and service agents around the globe, a short video on
IRON MOTORS PROTECTION To provide protection against overtemperature, all WEG
WEG’s manufacturing facilities as well as information on other WEG products such as
motors 160 frame and above are supplied with 1 set of PTC thermistors embedded in the
inverters, soft starters, electronic components and others. It is a powerful tool for all
TOP QUALITY BEARINGS BENEFITS windings prior to impregnation. The thermistors are rated 155˚C to allow use of motor’s
engineers, especially for those whose busy lives cannot afford wasting precious time in
 PREVENTS WINDING full capacity, including overload and service factor. WEG mining motors frame 225 to 355 are
sourcing this information through the normal channels. If you do not have a copy yet, FAILURES
HIGH GRADE GREASE supplied with an additional set of 180˚C thermistors to allow use at ambient temperatures of 60˚C.
request one from your nearest WEG office.  ALLOWS USE OF FULL In addition, WEG motors can be supplied with other thermal sensors such as RTDs and
MOTOR CAPACITY
ON THE RUN thermostats upon request. These can be fitted to both the windings and bearings. A stainless steel
RE-GREASING SYSTEM nameplate is affixed to all thermally protected motors. The nameplate specifies the type of sensor,
its temperature range and connection diagram.
SUPERIOR SEALS
ANTI-
Anti-condensation heaters are supplied as standard for the new mining motor range 225
HIGH TENSILE STEEL SHAFT C O N D E N S AT I O N
frame and above. They are available for other frames upon request. They are designed to
H E AT E R S elevate the motor internal temperature 6 to 10˚C above ambient, hence preventing condensation
ENHANCED DESIGN FOR
from forming inside the motors, which otherwise could affect the
HIGH SPEEDS
insulation resistance.
SPIKE
NO FORCED VENTILATION
REQUIRED R E S I STA N T
Spike-resistant wire is a new technology developed as a result of
WIRE studies on the effect of modern IGBT drives on AC motors. The secret
VPI AND CONTINUOUS BENEFITS is in the enamelling process, which ensures superior insulation in
RESIN FLOW Shown: Typical Data Sheet (top), Motor Curves (left), and
 GUARANTEED order to protect all turns against the rapid voltage rise times
Dimensional Drawing (above).
IMPREGNATION PERF ORM ANCE WITH LATEST (dV/dt). The industry has traditionally utilized 2 types of wire
DRIVES insulation: grade 2 (8 layers of standard enamel) and grade 3(12
EXTENSIVE R&D ACTIVITIES QUALITY PERFORM ANCE  RELIABILITY layers of standard enamel). This technology no longer meets the
 LO N G E R L I F E E X P E CTA N C Y demands of modern drives, which created the need for advances in
QUALITY SYSTEM
WEG, as an ISO9001 company accredited by BVQI from
FULL TECHNICAL SUPPORT wire insulation. With the support of its chemical division, WEG has
England, had its quality system approved by the most
developed its own inverter rated enamel, resulting in the superior
demanding standards such as CSA, UL, JET CESI, PTB,
LEADING TECHNOLOGIES dielectric and mechanical properties of WEG’s insulation. Implemented in WEG's own wire
WEG MOTORS ISO 9001 Germanisher Lloyd, SAA and SABS.
drawing centre, this feature is now standard on all WEG motors.
Page 1
 D E S I G N P A R A M E T E R S M O T O R C O N S T R U C T I O N

STA N DA R D S WEG motors are designed and manufactured in conformance with the relevant IEC and AS
standards. This includes standard dimensions, performance characteristics, vibration limits, run-
out and other general tolerances. However, compliance with the standards is only the
minimum requirement for WEG. Although the standards are well thought out by motor experts,
they can be of a general nature. In addition, the time elapsed between two consecutive
revisions of the standards imply they do not always keep pace with rapid technological
advances and market demands. We understand these limitations, we therefore step ahead
incorporating the most modern technology into our products. Our engineers take into
consideration the harshest applications the motors can be subjected to, combining the
recent developments from WEG’s R & D Department with our customers’ needs. WEG is
thus setting the standards in the marketplace. WEG is an international company and as such
capable of offering motors manufactured according to other major standards such as NEMA,
CSA, UL, JET and SABS to cite a few. Custom-built products are also available from WEG.
60˚C AMBIENT Electric motors are installed in many different environments, where the ambient temperature
may vary widely, commonly from 5 to 40˚C. The mining industry, however, sets forth a more
BENEFITS demanding requirement: the suitability to operate at higher ambient temperatures, usually
 NO DERATING REQUIRED
around 45 or 55˚C. WEG motors are designed with low temperature rise, high
 QUICK DELIVERY TIME temperature grease, low bearing temperature and high grade insulation, and hence
 C A P I TA L S AV I N G S are mechanically and electrically sound to operate at ambient temperatures of up to
60˚C. All low voltage motors are also guaranteed to operate down to -20˚C and lower. Contact
your local WEG office to confirm application demands and motor suitability.
HIGH GRADE WEG motors are made of high grade cast iron material. There are basically three
CAST IRON densities used in manufacturing electric motors: FC-100 (the industry standard), FC-150 and
FC-200. WEG uses exclusively FC-200, the same density mandated by international
MOTORS
standards for explosion proof motors. In addition, WEG motors are designed to provide the
highest mechanical resistance. The frames are provided with fins designed to improve heat
dissipation and adequately spaced to minimise air blockage due to build up of dirt.
MOUNTING As WEG motors are manufactured with high density cast
C O N F I G U R AT I O N S iron and designed to provide the highest mechanical
strength, they can be mounted in all possible
BENEFITS configurations. Every low voltage, off the shelf WEG
 REDUCE INVENTORY COSTS motor from 63 to 355M/L frame can be mounted in
 INCREASED MOTOR LIFE any position, horizontal or vertical, providing the maximum axial and radial thrusts as
E X P E CTA N C Y
stated in WEG’s catalogues are not exceeded.
FIXINGS AND All fixing bolts are made of corrosion-resistant material. The nameplate is made of
grade 316 stainless steel, and fixed to the motor by means of stainless steel rivets. All
FINISH
motors are painted to WEG plan 201, which consists of surface preparation to grade Sa 2.5,
one coat of primer paint and a finish coat of synthetic alkyd enamel. Other paint plans, e.g.
special paint for highly corrosive industrial environments, are available on request.

V O LTA G E A N D
FREQUENCY
BENEFITS
 STOCK MOTOR SUITS MOST
POWER SUPPLIES WORLDWIDE
CAST IRON The advantages of cast iron over aluminium or pressed metal
WEG W21 range is designed based on a multi-voltage concept, i.e. the motors are are well known by all engineers and motor experts. WEG
suitable to operate at a combination of voltages and frequencies as follows: FAN COWLS
offers cast iron endshields and flanges in all motors, including
Up to 100 frame (inclusive) From 112 to 355 frame BENEFITS the aluminium frame line (from 90 frame). In addition, all
Connection 50Hz 60Hz Connection 50Hz 60Hz WEG motors frame 160 and up are supplied with cast
 SUPERIOR MECHANICAL
D 220-240V 254-276V D 380-415V 440-480V RIGIDITY iron fan cowls. Smaller frames, up to 132, are supplied with
Y 380-415V 440-480V Y 660-720V 760-830V  C O R R O S I O N - R E S I STA N T pressed metal fan cowls as standard. However, stainless steel
The mining range is designed for 415V (in D up to 100 frame and in Y from 112 and above).  LONGER LIFE fan cowls are available on request.
WEG also manufactures motors from 110V up to 13,800V, available on request.

It is not unusual to see motors overloaded for long periods of time. The most common causes OVERSIZED WEG motors are manufactured with oversized cast iron IP66
C O N STA N T terminal boxes. The W21 range is supplied with a rectangular
OVERLOAD are load and voltage fluctuations. To guarantee trouble free operation, WEG motors are CAST IRON
generally designed with a 1.15 service factor, hence with the capability to cope with a terminal box; the mining motors with a diagonal split box. In
T E R M I N A L B OX addition, all mining motors 160 frame and above have one
15% continuous overload when installed in an ambient temperature of 40˚C.
BENEFITS additional accessories terminal box for termination of
 PROVIDES SUFFICIENT thermistors and other thermal sensors if any. The boxes come
15 0 % In the course of their lives, electric motors may be ROOM F OR TERMINATING with 1 or 2 drilled and tapped holes (see motor catalogue) and can be rotated in 90˚ intervals.
subjected to momentary overloads . These can VARIOUS SIZES OF CABLES The mining motor is supplied with gland plates for frames 225 to 355M/L.
OVERLOAD
originate from voltage sags, load variations etc. If
C A PAC I TY not properly selected, motors can stall or even fail
BENEFITS prematurely. WEG motors are designed to INCREASED For many years the industry standard terminal block did not
 RELIABLE OPERATION withstand a momentary overload of 150% for have any barriers between the poles to eliminate the possibility
S AFETY
 RUGGED DESIGN up to 2 minutes (as per IEC 60034-1), providing of cable terminations rotating and accidently causing a short
this is a sporadic event.
TERMINAL
circuit. WEG has stepped ahead standardising on a new
BLOCK increased safety terminal block, standard in all low voltage
motors. This new block effectively prevents the incoming leads
from touching one another. No doubt a big advantage from a
safety perspective.
Page 2 Page 3
 BEARINGS AND L U B R I C AT I O N R O T O R S A N D S H A F T S

QUALITY WEG motors are fitted with the highest quality bearings. Approved LOW LOSS WEG has one of the world’s largest die cast
BEARINGS brands include SKF, NSK and FAG. Bearings are selected to withstand high HIGH QUALITY aluminium rotors. The advantages of aluminium
mechanical loads, quiet operation and long life. Motors are designed and rotors are lower inertia, higher starting torque,
BENEFITS
ROTORS
manufactured in a way to minimise electromagnetic and mechanical forces higher mechanical rigidity, to cite only a few. WEG
 HIGHER THRUST on the bearings. In addition, bearings are selected with C3 clearance (from BENEFITS also makes copper bar rotors. These are carefully
CAPABILITY
160 frame) to provide for thermal expansion. Ball bearings are fitted as standard in the W21 range  SUPERIOR MECHANICAL built to minimise stress and improve motor
 LOWER BEARING and up to 200 frame in the mining motor line. Larger motors are supplied with a DE roller bearing RIGIDITY efficiency. The rotors are precisely machined in CNC
TEMPERATURE
to improve radial load carrying capability, a significant advantage for pulley applications. Thrust  B E TT E R S U I TA B L E F O R lathes to guarantee an even air gap. They are built
HARSHER DUTIES WITH HIGH
bearings are also available for applications with high axial loads. with low electrical loss magnetic steel laminations,
N U M B E R O F STA R T S
which are thermochemically treated to improve efficiency and minimise mechanical stress.
 LONGER LIFE

In recent years a number of cases of premature bearing failure has been reported. The culprit is
PROTECTION
the common mode voltage and dV/dt generated by modern IGBT PWM drives. WEG’s R&D
AGAINST Department has been researching this subject extensively for more than 5 years. As a result, WEG The bearings are not the only load carrying component in an electric motor. The shaft is
BEARING HIGH TENSILE
was the first motor manufacturer to offer effective protection against bearing currents or STEEL SHAFT equally subjected to all thrusts applied to the motor. WEG uses AISI 1045 steel as standard.
CURRENT (EDM) EDM. The solution consists of an improved motor design to However higher mechanical loads are normally encountered in pulley type applications, and
minimise asymmetries and the addition of an insulated bearing BENEFITS hence in addition to roller bearings on the drive end, WEG utilises a high tensile steel,
BENEFITS
or bearing housing, plus a shaft grounding brush. This is  PREVENTS FLEXING which is 300% stronger than the industry standard steel. This is standard from 280 to
 ELIMINATES EDM BEARING UNDER LOAD
FAILURES supplied for frames 315 and larger every time WEG is made 355M/L frame. All motors are provided with a captive keyway and key, as well as drilled and
aware that the motor is going on a drive. In larger frame  MINIMISES FATIGUE tapped shaft. Perpendicularity, concentricity and run-out comply with IEC 72/AS 1359 standards.
 LOWER MAINTENANCE ADDING TO LIFE TIME
COST motors, to decrease maintenance costs and overcome the PERFORMANCE Special shaft dimensions and stainless steel shafts are available on request.
 PREVENTS UNDESIRED problem of high insulation capacitance, WEG offers an insulated
MACHINE SHUT DOWN bearing housing and standard bearing arrangement. For more technical information consult our
paper entitled The Unseen Truth Behind Motors fed by Inverters. All WEG rotors are dynamically balanced
PRECISE
in computerised machines near or at
BALANCING
Grease Nipple their rated speeds, including larger 16
ON-THE-RUN Oversized high quality bearings is certainly a big plus of WEG FO R LOW ton rotors. Balancing is done in two
RE-GREASING motors. However, to ensure proper operation and long life, bearings V I B R AT I O N planes to minimise vibration. Balancing is
need to be lubricated periodically. WEG motors are provided with carried out to grade N as per IEC 34-14/ AS
FACILITIES
grease nipples and grease outlet to allow for on-the-run 1359-50 standards. Larger motors are
BENEFITS lubrication. The grease outlet allows the old grease to be flushed balanced to grade R as standard. Special
 PERMITS REGREASING out whilst the new grease is pumped in, thus forming a flush balancing is available on request.
WHILE MACHINE IS RUNNING through system which is standard for all motors 160 frame and
 ENSURES OLD GREASE IS above. Frames 63 to 132 have sealed (ZZ) bearings. The lubrication Grease Bleeder
FLUSHED OUT Outlet
data is permanently engraved on a 316 stainless steel nameplate Electric motors can be installed in a multitude of
 MINIMISES RISK OF OVER
fixed to the motor, thus being readily available to maintenance personnel. SUPERIOR
LUBRICATION AND environments, some more aggressive than others.
OVERHEATING MECHANICAL
They must be duly protected against the ingress of
SEALS fluids and foreign matters to prevent contamination
DESIGNED FOR of the grease and windings. Failure to do so may
LOW BEARING WEG has recently redesigned their endshields to include fins and THE SPECIFIC result in a motor breakdown. Whereas the IP grade
improve heat transfer properties, aiming to decrease bearing ENVIRONMENT
TEMPERATURE is an important parameter, it does not guarantee
temperature. It is known that most motor failures are caused by motor performance, as it is not bound to any
TOP QUALITY either winding or bearing faults. Over 50% of bearing failures, in
GREASE particular type of mechanical seal. The W21 range
some industries, are associated with poor or incorrect lubrication. is fitted with general application v-ring seals in
While it is extremely important to follow the re-lubrication instructions, it is crucial to have the all foot mounted motors and oil seals in flange
BENEFITS
correct lubricant from the start. WEG motors are supplied with Alvania R3 (-35 to 135˚C) grease for mounted motors. The WEG mining motor line, however, is fitted with taconite labyrinth
 LOWER MAINTENANCE frames up to 132 (ZZ sealed bearings) and Polyrex EM grease for frames 160 to 355M/L. Unirex
COSTS seals to provide the best possible protection in the typical dusty and wet environments of
is a high temperature grease, that provides superior mechanical stability in high vibration mines and heavy industry. This ensures superior mechanical protection. Additionally, the
 LONGER LUBRICATION
INTERVALS applications such as screw compressors. In addition, it has great rust inhibiting and wear non-ferrous labyrinth plate does not attract the small abrasive magnetic particles evident in
 LONGER BEARING LIFE resistance properties. For special applications such as high speed, high mechanical load, low or some separation processes. WEG mining motors offer the ultimate protection for the mining
high ambient temperatures special lubricants may be required. Oil seal used in flange mounted motors. and heavy industries.

Page 4 Page 5
 H I G H E F F I C I E N C Y -
C O O L I N G & N O I S E L E V E L S
S U P E R I O R P E R F O R M A N C E

FANS With the aim of reducing noise levels and improve cooling efficiency, WEG has redesigned the fans E XC E E D I N G WEG has many years of WEG vs MEPS Efficiency
and fan cowls to produce one of the quietest electric motors on the market. The W21 range is STA N DA R D S experience supplying motors to 98.00

BENEFITS supplied with anti-static polypropylene fans from 63 to 315 frame, and aluminium in 355 frame. markets where minimum
96.00

94.00
 LOW NOISE This minimises windage losses, thus increasing motor efficiency. Alternatively, cast iron or aluminium BENEFITS efficiencies are mandatory, with 92.00

 F A N S A R E F U L LY fans can be supplied on request for all frames.  GUARANTEED PERFORMANCE heavy penalties in force for

Efficiency
90.00
INTERCHANGEABLE MEPS Eff.

The mining motor line is supplied with cast iron fans in all frame sizes. The fan is secured to  ENERGY SAVINGS non-compliance. As a CSA/UL 88.00
WEG E2 range
WEG E3 range

 EFFICIENT COOLING  ACCESS TO THE MOST

ENSURES LOW MOTOR the shaft by means of a steel key or circlip. All fans are bi-directional, thus allowing selection of certified laboratory, WEG’s 86.00

ADVANCED TECHNOLOGY IN 84.00

TEMPERATURE RISE direction of rotation in situ. expertise in this area is
AN OFF-THE-SHELF PRODUCT 82.00

extensive. The W21 line

Although WEG Premium Efficiency and Top Premium Efficiency motors do not need as much airflow, 80.00
0.75 1.1 1.5 2.2 3 4 5.5 7.5 9.2 11 15 18.5 22 30 37 45 55 75 90 110 135 150 160

due to the decrease in heat-generating losses, they are still manufactured with the same fans as represents the latest motor KW

the W21 line. The advantages are interchangeability of parts and, more importantly, an extremely technology. Low loss
low temperature rise. laminations, high purity larger gauge copper wire, otpimised design based on finite elements
technique, spike-resistant wire are only a few of the many features of WEG’s new range. The
NOISE LEVELS result is a reliable, high quality energy efficient motor, which exceeds MEPS (table B2).
In addition, WEG produces a Top Premium Efficiency Range, one of the world’s most
efficient motor. Efficiencies are tested by summation of losses as per IEC 34-2 (AS 1359-33).
The technical data for these lines can be found in WEG’s Electronic Catalogue or on
pertinent product catalogues.
The information therein is
based on average test data,
hence can be used for pay-
back calculations.

TESTING
Noise is measured at no load 1m from the machine as per IEC 34-9 (AS 1359-51). The noise levels WEG has 7 fully accredited
can be found in the pertinent product catalogues or in the WEG Electronic Catalogue. WEG motors motor laboratories (certified
have been designed with the new Workplace Health and Safety noise level standards in by UL and CSA), equipped
mind. Hence they are one of the quietest motors in the marketplace. Above are typical noise level with modern high accuracy
graphs showing WEG motors against the industry average. test equipment. Our
Typical vibration test report Typical noise level test report
laboratories are capable of
NO NO FORCED COOLING REQUIRED
Vector control technology permits the operation of standard carrying out full load tests up to 10,000kVA at voltages from 110V to 15,000V in 50 or
FORCED induction motors at very low speeds for extended periods of 60Hz. The data is supplied by high accuracy instruments to a dedicated computer,
V E N T I LAT I O N time. However, operation below rated speed affects the which controls the whole process. The data is downloaded straight to the computer and
REQUIRED cooling efficiency of the shaft-driven fan, which results in reports are automatically issued. A fully
increased motor temperature rise. To overcome that qualified test engineer gives the initial
BENEFITS limitation, engineers developed derating factors and forced commands and oversees the whole process.
 LOW C A P I TA L C O ST cooling fan systems. A practical rule dictated either of the two The instruments are calibrated by WEG’s
 LOWEST RUNNING COST had to be applied for operation at or below 40Hz. own metrology department, that in turn has
 LOW E ST I N STA L LAT I O N C O ST their instruments calibrated to international
With WEG’s new Optimal Flux Technology (patented) this requirement is now a thing of the
past. Each CFW09 (VECTRUE Inverter) has the electromagnetic circuit model of the appropriate WEG standards. Every WEG motor undergoes a
E2 (previous PHEM) motor built in. By carefully optimizing the V/F ratios whilst the inverter is series of tests on the production line,
operating, the current (and therefore the motor heating) can be precisely controlled. The end result these include hi-pot test prior to and after
is a motor and drive package which must be regarded as a truly integrated solution to a long impregnation. In addition, type tests are
standing and expensive problem. carried out on samples from each low
When a CFW09 inverter is used in conjunction with WEG E2 range of motors (previous voltage motor batch. All high voltage
premium high efficiency range) and the continuous operating speed is 10Hz or above there is motors are type tested as standard.
no requirement for external forced cooling. This represents an “Up Front” cost saving to the end Special tests such as overspeed and shaft
user. Since there is no cooling fan, this also means there is also no power nor control induced voltage are carried out upon
infrastructure. Furthermore, the absence of a fan motor yields ongoing energy savings with respect request . Inspectors are welcomed to
to fan energy usage. This alone may represent a saving of hundreds of dollars per year. witness any tests or inspect our facilities.
This system is only valid for use only with WEG E2 Motors and CFW09 Variable speed Drives. WEG motors, performance guaranteed.
Typical type test report
Page 6 Page 7
 H I G H O U T P U T LO W V O LTA G E A N D H I G H V O LTA G E M O T O R S

RANGE In high voltage or low voltage high output motors, WEG has two main lines: the High I M P R E G N AT I O N All motors are impregnated using the latest VPI technology. WEG uses only solvent free
Performance, and the Master line. These range up to 1,200kW in low voltage and 20,000kW in epoxy resin of class H temperature. Prior to impregnation the winding is pre-heated to dry
high voltage. These lines are available as totally enclosed or open drip proof, squirrel cage or slip BENEFITS out any moisture. It is inserted into the VPI tank, where vacuum is created to remove all air.
ring (Master line only). In addition, WEG also manufactures a range of cast iron frame low  SUPERIOR MECHANICAL The stator is then immersed in resin and pressure is applied to push it effectively through the
RIGIDITY
voltage slip ring motors (the FAF line) and ODP motors (the AGA line). slots, leaving no gaps. The
 IMPROVED HEAT process is controlled by a
DISSIPATION
computer, which monitors the
 LONGER INSULATION LIFE
HV INSULATION SYSTEM insulation capacitance and
stops the process automatically
WIRE INSULATION: The stator coils are manufactured when the pre-set values have
Master Line using either a rectangular enamelled copper wire coated been reached. The computer
with fibre glass or bare copper wire coated with mica accurately measures and checks
base tape with a polyester film on both sides to increase that the coils have been
its mechanical strength. The type or wire used depends on covered in resin and that the tapes have absorbed the maximum amount of resin possible.
the voltage and application the machine will be used in. Afterwards the resin is cured in a temperature controlled oven and the complete stator is
MAIN INSULATION: The coils are then pressed and expanded in order to conform with the pre- tested prior to insertion into the frame.
set dimensions. Next they are taped with a porous mica tape, in an banding machine. The
H Line
thickness of the insulation depends on the machine voltage and method of starting.
I N V E R T E R R AT E D As stated before, the modern IGBT PWM inverters generate voltage spikes and high dV/dts,
PROTECTION AGAINST CORONA: WEG uses which stress a motor’s insulation. Although WEG motors are built with spike-resistant wire and
two types of protection against corona: I N S U LAT I O N
enhanced insulation, additional measures must be taken with high voltage motors which
Conductive Tape: made of polyester base BENEFITS otherwise could be severely affected, especially due to partial discharges caused by the
non-woven material impregnated with a  TRUE INVERTER RATED voltage spikes and the heat generated by the harmonics. No doubt that an inverter fed motor
conductive varnish composed of graphite MOTOR should have reinforced insulation and corona protection even in voltages as low as 3.3kV.
particles, which prevents corona eliminating  TROUBLE FREE OPERATION WEG, as a top quality manufacturer, has stepped ahead. In defence of the customer’s interest
insulation stress. This tape is applied onto the WITH MODERN DRIVES
WEG has incorporated some minimum design parameters for all inverter fed motors
straight part (the one that is in contact with  LONGER LIFE such as insulating to 150% of rated voltage, corona protection, spike-resistant wire,
AGA Line
the stator core) of the coil. Whereas the among other features.
industry standard is to use corona
protection for voltages above 6,000V, to
enhance motor life WEG uses it on all The H, AGA and FAF lines are made of high density cast iron. With the H line WEG makes
FRAME
motors with voltages above 4,000V. one of the world’s largest cast iron frames (up to frame IEC630). WEG thus offers all the
Semi-conductive tape: made of polyester base material impregnated with silicon carbide, its BENEFITS advantages of cast iron up to 1,800kW. The Master line is made of fabricated steel, with
function is to equalise the potential gradient in the region where the coil exits the stator core. This  HIGH MECHANICAL excellent structural strength and low vibration, suitable to operate under the most severe
is an area of great electric stress due to surface discharges. RIGIDITY conditions. The fabricated steel construction allows high flexibility in design, a multitude of
 S U I TA B L E F O R H I G H LY cooling methods and a high output/weight ratio.
FAF Line MECHANICAL PROTECTION Most high grade insulation materials dot not have sufficient AGGRESSIVE ENVIRONMENTS
mechanical strength and can be damaged during the winding process. WEG uses a non-woven  SPACE SAVINGS
polyester tape and a shrinkable fibre glass tape as a total mechanical protection for the coils.  CUTS DOWN ON
I N STA L LAT I O N C O ST S
BENEFITS INSULATION BETWEEN COILS This is achieved by means of a fibreglass laminated material
 TOP QUALITY INSULATION impregnated with epoxy resin. Due to its excellent mechanical and electrical properties it is also
 HIGHER CORONA used to tie the coil heads and as a non-magnetic wedge.
I N C E P T I O N VO LTAG E
WEDGING WEG uses either non-magnetic or magnetic materials as slot wedges, depending on
STATO R WEG motors are manufactured with low
 GREATER MECHANICAL
R E S I STA N C E electric loss magnetic steel. The
motor characteristics and application.
laminations are coated with insulating
 LONGER LIFE
CONNECTION The winding tails are jointed and welded. A binding electrode is added until all material to decrease foucault currents (eddy
gaps have been filled. The connections are then insulated with a porous mica tape. The current losses). The stator core is then
connection with the power leads is done by means of a copper strand, which is tied around the pressed and bound by a steel plate, which
leads and coil ends. Again this connection is welded and is covered with a binding electrode until secures it in place in the frame. The larger
all gaps are filled. The final step consists on insulating the exposed conductors with a porous frames have radial channels, which in conjunction with the cooling system improves the heat
mica tape. dissipation decreasing overall motor temperature.

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 H I G H O U T P U T LO W V O LTA G E A N D H I G H V O LTA G E M O T O R S

ROTORS WEG makes squirrel cage rotors, die cast aluminium and copper bar, as well as wound rotors, COOLING The AGA and FAF lines are provided with a bi-directional fan, thus allowing on-site change of
designed to provide high torque and long life. Aluminium rotors are manufactured in-house, direction of rotation. The H line is designed with internal and external cooling fins and fans.
BENEFITS as a one piece solid rotor with built-in fins, thus optimising heat dissipation and ensuring The internal fan and the four air ducts create a tunnelling effect that homogenises the
 COSTS LESS TO RUN excellent mechanical rigidity. internal temperature cooling the DE part of the winding and bearing, which are not
 MINIMISES FATIGUE directly cooled in standard TEFC motors. This eliminates hotter spots in the insulation,
THUS LASTING LONGER
Special care is taken in the construction of copper ensuring its dielectric strength is the same all over. Also, the DE bearing operates at
bar rotors. The short circuit ring is brazed to the low temperatures, thus prolonging the lubrication life.
bars using a silver solder, thus ensuring perfect
electrical connection and high The Master line can be designed with a multitude of cooling systems, e.g. self-cooled,
mechanical rigidity. The rotor is then air-air heat exchanger or air-water heat exchanger. The type of cooling selected
washed, dried and impregnated with depends on motor size and application. In addition, the rotor and stator are built with radial
epoxy resin for optimum heat ventilation channels to homogenize internal temperature and improve heat dissipation.
transfer and to effectively secure the bars in the slots. This prevents fatigue and
minimises stress, a common problem with copper bar rotors. TESTS At every step of the production process, WEG carries out a number of tests. This is part of the
company’s stringent quality control. After assembling, the finished product is again fully tested
Wound rotors are insulated with NOMEX and impregnated with solvent free BENEFITS in a computerised laboratory, capable of doing full load tests up to 10,000kVA. All test results
epoxy resin. The slip-rings are made of stainless steel, thus lasting longer than  GUARANTEED QUALITY are recorded and fully traceable, as per ISO9001 standards. The chart below shows some of
normal brass rings. Slip-ring motors can be provided with manual or automatic  SPECIAL TESTS AVAILABLE the tests carried out by WEG. Special tests are available on request.
brush lifting device, developed with state-of-the-art technology to prevent  ONE OF THE WORLD’S
LARGEST TEST FACILITIES
premature brush and slip-ring wear. This device has been in service for years
in many companies around the world, which now enjoy thousands of  CERTIFIED BY CSA
Slip ring motor with
brush lifting device.
dollars of savings in brush replacement and general maintenance.

BEARINGS WEG high voltage motors can be supplied with rolling

element (grease or oil lubricated) or sleeve bearings,
selected from the world's best manufacturers. All motors are
provided with facilities to allow re-lubrication whilst the machine
is running, thus eliminating downtime. Sleeve bearings allow
easy inspection and maintenance without requiring uncoupling
of the driven machine, hence decreasing maintenance costs.

BALANCING
WEG balances all high voltage motors to grade R as per IEC 34-14 (AS 1359-50)
BENEFITS
standards. This minimises the transmission of vibration to the driven load and nearby
 LOW VIBRATION equipment, minimising bearing wear and improving overall equipment life.
 LONGER BEARING LIFE WEG has a highly specialised engineering team, whose job is to offer high quality, cost-
DESIGN
F L E X I B I L I TY effective solutions to customers’ needs. We can custom-built our motors to suit virtually any
The main terminal box is made of fabricated steel or cast application. Special frame or shaft dimensions, high torque, special voltages, NEMA frames,
T E R M I N A L B OX iron, incorporating a pressure relief device to alleviate the BENEFITS and much more. WEG’s will to help and its flexible design has already saved its customers
build up of internal pressure due to short circuits, thus  H I G H Q U A L I TY, C O ST many thousands of dollars. There are a number of options that can be added to our standard
minimising the risks of accidents to operators. It can be EFFECTIVE SOLUTIONS product, some are:
rotated at 90˚ intervals, and is sealed by means of a rubber  C U T S D OW N I N STA L LAT I O N RTDs (PT-100, Ni-20, CU10) Sleeve bearings Thermocouple type J
AND MAINTENANCE COSTS
gasket to prevent penetration of dust and liquids into the Noise suppressors Bearing thermometer Special painting
 ENSURES RELIABILITY AND
motor. Lightning arrestors and surge protection capacitors can GOOD TIMING EX-e (PTB certificate) WPI, WPII, IP56, IP65 Surge capacitors
be fitted on request. Termination of accessories is done in Ex-n Vibration sensors Lightning arrestor
one or two cast iron terminal boxes, located at the opposite Ex-p
side of the main terminal box as standard (can also be mounted on same side). Extra
S P E E DY When it comes to delivery time, you will find that WEG is by far quicker and more precise.
terminal boxes for segregated phase arrangements can be provided upon request. All terminal
DELIVERY TIME A just-in-time production system and a self-sufficient manufacturing plant ensures every
boxes are fitted with threaded metric holes as standard (other threads available). Low voltage
order is processed quickly and efficiently, and what’s best, always with the high quality of
motors are supplied with premix isolators and high voltage with porcelain insulators.
the WEG product. This is why we can guarantee our quoted delivery times.
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 S U P E R I O R
QUALITY SYSTEM
WEG MOTORS ISO 9001
QUALITY AND
PRODUCTIVITY
PROGRAMME
(PWQP)
The most prestigious business accolade in
Brazil, the National Quality Award, has been
awarded to WEG. This award is open to all
companies established in Brazil, past winners
include Alcoa (1996) and IBM(1992). Founded
in 1991, based on the same criteria of the
Malcolm Baldridge Award in the USA, the NQA
is a reward for excellence in performance,
management, quality, productivity, goods
and services.
Q U A L I T Y
At WEG quality is not just a word used to impress. To WEG Quality
is a natural process, an integral part of our company’s policy.
WEG’s commitment to continuous improvement is based on the
following key points:
The PWQP programme is divided into commitment to quality and organisation to quality. It
defines the processes to be adopted and the goals to be accomplished allowing the company
to be more efficient and competitive. A profit sharing scheme, whereby 12% of the gross profit
is shared among the employees, is used as an incentive.
STANDARDISATION AND TECHNOLOGY On-going research and product development is WEG’s
permanent concern. As new technologies are developed and implemented into production,
WEG immediately makes that a standard for its products, aiming to offer cost-effective high-
tech products to the market.
QUALITY CONTROL CIRCLES (QCC) Created to encourage employee participation in the
administration process, the groups are formed by volunteers of each department that gather
once a month to discuss ways of improving work procedures and methods. They are real
catalysts of ideas, promoting creativity throughout all the hierarchy levels.
CONTINUOUS TRAINING WEG regards training as an investment in the company’s greatest
assets, its employees. Currently 3% of the gross turnover is invested in training, including the
sponsoring of master degree and PhD courses. The result is a highly trained motivated work
force, better prepared to serve WEG’s clientele achieving high level of customer satisfaction.
WEG’S QUALITY POLICY
1. COMMITMENT TO QUALITY
2. ORGANISATION TO QUALITY
3. STANDARDISATION AND TECHNOLOGY
4. EDUCATION AND TRAINING
5. PARTICIPATORY MANAGEMENT (QCC)
As a result of WEG’s strict quality control and quality orientated management, WEG was one of
the first companies worldwide to achieve ISO9001 certificate.
But at WEG quality is a much wider concept. The company takes pride in being self-sufficient,
thus able to work with stricter quality controls. WEG draws and enamels its own wire, produces
enamel and resins, stamps its own lamination, casts its own frames and parts, injects its own
aluminium rotors, does its own design, tests all products and provides engineering services to
the market. WEG is fully verticalized, its manufacturing facilities comprise of:
 Wire Drawing and Enamelling Centre  Engineering Division
 Aluminium Injection Centre  R & D Divisions
 Stamping Centre  Quality Control Department
 Machining Centre  Customer Service Department
 Chemical Plant (produces enamel, resin, varnish and paint)
 General Manufacturing Plants
Whatever the needs, whatever the standards, whatever the application, WEG, as one of the
world’s largest motor manufacturers, is able to meet the requirements and demands of the
global market in both AC and DC motors. WEG invests an average of US$50 million per year
into the most modern manufacturing and testing technologies, as well as R&D and training.
WEG produces a wide range of low and high voltage motors with high quality and reliability
as a parameter in ensuring longevity and lengthy maintenance-free operation.
Page 12
F U L L T E C H N I C A L S U P P O R T
COMMITMENT WEG is not just a product manufacturer. WEG takes pride in the vast service
TO SERVICE and support network available to their customers. Factory trained engineers
and a highly specialised sales team are employed by WEG
branches. Design, installation, maintenance, on site troubleshooting,
technical seminars and product training are only a few of the
services we offer. WEG is not only one of the world’s top motor
manufacturers, but a service provider. WEG is committed to
providing solutions for industry.
SUPPORTING A vast range of technical literature is made available to all customers. The Electric Motor
Manual, product catalogues, AUTOCAD scale drawing software, electronic catalogue, installation
TECHNICAL
and maintenance manuals, service network contact details, and much more. WEG customers
LITERATURE also benefit from a variety of training seminars and technical papers such as: AC Motor
Maintenance, AC Motors after Drives, Motor Protection, What High Efficiency Really Means, etc.
Interested? Ring WEG now for further information or visit our web site - www.weg.net
1, 5 0 0 WEG customers are assisted by resident factory trained
engineers, ready to help you with cost-effective, energy
E N G I N E E R S AT
saving solutions. Further back-up is provided by an army of
YO U R S E R V I C E 1,500 engineers in different divisions such as engineering,
R&D and customer service, equipped with the most modern
tools, laboratories and engineering programmes.
E XT E N S I V E R & D When it comes to research and development WEG shows how
serious they are. As a proof of its long-term commitment to the
ACTIVITIES market and its customers, US$35 million is invested every year.
The electric motor R & D committee is headed by WEG’s R & D
manager and technical director as well as world renowned
researchers from leading universities around the world such as
North America, Germany and Brazil. WEG combines strong
theoretical knowledge with their practical expertise to promote
constant product innovations and developments, leading the
way in the marketplace. Additionally, the strong interaction between the different R & D
divisions, e.g. the electric motor and drives divisions, gives WEG the know-how to develop new
technologies to benefit its customers.
To WEG the engineering of the best technical - economical solution and the supply of the
AFTER SALES
products is only the first step. WEG sees the after sales service as an integral and crucial part
SERVICE
of the package it offers to its customers. A highly specialised authorised service network is
made available when and where needed. WEG service agents provide customers with an
opportunity to call on local technicians to carry out all aspects of service, repairs, and new
motor sales. Large spare parts inventories and product interchangeability ensures products can
be easily and quickly repaired at all times.
Page 13