Beruflich Dokumente
Kultur Dokumente
ABB LT Motors
Contents
Electrical
Electrical features 13
Starting method for AC motors 14
Typical motor current and torque curves 15
Comparison between starting methods 15
Starting time 16
Example of starting performance with
different load torques 17
Electrical braking 18
Duty types 20
Protection accessories 22
Guide for fuse protection 22
Voltage drop along cable 23
Negative sequence withstand characteristics 23
Power factor improvement chart 24
Mechanical
Mechanical Features 25
Exploded view of HX motors 26
Pulley diameter 27
Permissible radial forces 28
Permissible axial forces 29
Product Range
Range
Output 0.18 ...500kW; 0.25 ...675hp; according to IS 325
Voltage 220 ... 660V
Frequency 25 ... 60Hz
Duty S1 ... S8 according to IS:325
Ambient Temperature -20ºC ... 65ºC
3
Design Variants
Electrical Mechanical
Non standard voltage and frequency variations Non standard mounting dimensions
AC variable speed drives Special shaft extension
High torque motors Double shaft extension
High slip motors Separately ventilated motors
Motors for frequent start / stops / reversals Low vibration and noise level
Frequency 25 to 60 Hz Brake motors
Special performance requirements Special bearings and lubrications
Class H insulation Tacho mounting / SPM mounting
Voltage 220V to 550V Non standard paint shade
Alternative terminal box position
IP 56 protection
Special shaft material
Special size of terminal box and terminal arrangements
Surface cooled motors
SS name plate
Non standard keyway
Epoxy gelcoat on overhangs
Space heaters
Thermistors, RTD , BTD
Single compression / double compression glands
Note: Please refer to the company for details of special designs offered.
4
Standards
ABB Motors are designed to ensure that performance complies with IS:325. HX/M2BA Motors are totally-enclosed three-phase
squirrel cage type complying with relevant Indian Standards.
List of Indian Standards applicable to low-voltage induction motors are as given below:
IS No. Title
IS 900:1992 Code of practice for installation and maintenance of induction motors (second revision)
IS 2253:1974 Designation for types of construction and mounting arrangement of rotation electrical machines
(first revision)
IS 4691:1985 Degrees of protection provided by enclosure for rotation electrical machinery (first revision)
IS 4728:1975 Terminal marking and direction of rotation for rotating electrical machinery (first revision)
IS 7538:1975 Three-phase squirrel cage induction motors for centrifugal pumps for agricultural applications
IS 8223:1976 Dimensions and output ratings for foot-mounted electrical machines with frame numbers 355 to 1000
IS 12075:1986 Mechanical vibration of rotating electrical machines with shaft heights 56mm and higher-measurement,
evaluation and limits of vibration severity (super ceding IS 4729:1968)
IS 12824:1989 Type of duty and classes of rating assigned to rotating electrical machines
IS 13107:1991 Guide for measurement of winding resistance of an a.c. machine during operation at alternating voltage
IS 13529:1992 Guide on effects of unbalanced voltages on the performance of three-phase cage induction motors
IS 13555:1993 Guide for selection and application of three-phase a.c. induction motors for different types of driven
equipment
5
Tolerances (as per IS:325-1996)
Item Tolerance
Efficiency (h)
By summation of losses
Motors up to 50kW -15 percent of (1 - h)
Motors above 50kW -10 percent of (1 - h)
Total losses applicable to motors above 50kW* +10 percent of total losses
Power factor (cosf) -1/6 of (1 - cosf) min 0.02 and max 0.07
Slip at full load and working temperature ±20 percent of the guaranteed value
Breakaway starting current with the specified ±20 percent of the guaranteed starting current
starting method (no negative tolerance)
Pullout torque -10 percent of the guaranteed torque except that after
applying this tolerance, the torque shall not be less than
1.6 or 1.5 times the rated torque
Moment of inertia or stored energy constant for ±10 per cent of the guaranteed value
motors above 315 frame
Mounting arrangements
IS:2253 and technically identical IEC 60034-7 specify two
possible ways of describing how a motor is mounted.
Code I covers only motors with bearing end shields and one
shaft extension. The code consists of letters IM, a further letter
and a number.
IM 1 00 1
International mounting
6
Mounting arrangements
CodeI/CodeII
Foot-mounted motor, IM B 3 IM V 5 IM V 6 IM B 6 IM B 7 IM B 8
IM 1001 IM 1011 IM 1031 IM 1051 IM 1061 IM 1071
7
Degree of protection
Degree of protection for rotating machines are indicated according to IS:4691 using the characteristic letters ‘IP’ followed by two
characteristic numerals for the degree of protection.
The first numeral indicates protection against contact and ingress of foreign bodies.
IP 5 Dust protected motors, Ingress of dust is not fully protected, but dust can not enter in an amount sufficient to interface with
satisfactory operations of the motor.
IP 3 Protected against spraying water, sprayed up to angle of 600 from vertical shall have no harmful effect.
IP 5 Protected against water, jets by a nozzle from any direction shall have no harmful effect.
IP 6 Protected against heavy seas, powerful jets from all direction shall have no harmful effect.
0 No protection 0 No protection
1 Protected against 1 Dripping water
solid objects shall have no
greater that 50mm harmful effect.
(e.g. hand)
4 Water splashed
4 Protected against from any direction
solid objects shall have no
greater that 1mm harmful effect
(e.g. wire or
strips)
5 Water hosed
5 Ingress of dust is against the
not totally enclosure shall
protected, but does have no harmful
not enter in effect (water jets)
sufficient quantities
to harm equipment
6 Water from
6 No ingress of dust powerful jets of
heavy seas shall
have no harmful
effects
8
Cooling Methods D-end and N-end
Cooling methods of HX/M2BA Motors are in accordance with The ends of motors are defined as D-end; the end that is
IS:6362. The motors are cooled by the method IC 0141, i.e. normally the drive end of the motor and N-end; the end that is
frame surface cooled, with external cooling fan on motor shaft. normally the non-drive end of the motor.
0
C
9
Effect of voltage and frequency variation
Almost without exception, the starting current decreases slightly more in proportion to the voltage. Thus for example 90% of rated
voltage the motor will draw slightly less than 90% of the starting current, approximately 87 to 89%. The starting torque is
proportional to the square of the current, the torque delivered at 90% of rated voltage is therefore only 75% to 79% of the starting
torque. Particular attention should be paid to these points if the electrical supply is weak and when starting techniques based on
current reduction are being used. The pull out torque is roughly proportional to the voltage.
If the saturation of the magnetic circuit is neglected, then the general effect of variation in voltage and frequency on the
characteristics of induction motor can be given as per the table below.
Table - Effect of variation of voltage and frequency on the characteristics of induction motor*
Height above sea level (M) 1000 1500 2000 2500 3000 3500 4000
Permitted output (% of rated output) 100 96 92 88 84 80 76
S2 S3
10
Motors for 60 Hz operation
Motors wound for a certain voltage at 50 Hz can be operated at 60 Hz, without modification, subject to the following changes in their
data.
Efficiency, power factor and temperature rise will be approximately the same as at 50 Hz.
1) IN = rated current
IS/IN = starting current/rated current
TN = rated torque
Tmax/TN = maximum torque/rated torque
TS/TN = starting torque/rated torque
11
Winding Connection
Single speed
Star connected windings for motors upto 2 hp and delta connected windings for motors above 2 hp are standard features. The
connection diagrams for single speed motors are given below:
D - connection Y - connection
Double speed
The difference in winding configuration and application necessitates different winding connections so as to accommodate maximum
power in a given frame.
- Motors with two separate windings are normally Y/Y connected upto frame size 160, larger motors are D/D, Y/D or D/Y
connected
- Motors with Dahalander connection, are in D/YY when they are designed for constant torque drives and Y/YY when they are
designed for fan drive.
2. Two separate
windings D/D
3. Dahlander-
connection D/YY
4. Dahlander-
connection Y/YY
12
Electrical features
hs - h
s= x 100 (%)
hs
When the motor is partly loaded the slip varies almost
linearly with the load.
13
Starting methods for AC motors
• The voltage drop in the supply network when starting the motor
• The required load torque during start
• The required starting time
Soft starters
UN
Soft starters are based on semiconductors, which, via a power circuit and a control circuit, initially IstR
reduce the motor voltage, resulting in lower motor torque. During the starting process, the soft UN = Rated net
starter progressively increases the motor voltage so that the motor becomes strong enough to voltage
accelerate the load to rated speed without causing torque or current peaks. Soft starters can also IstR = Start current
be used to control the stopping of a process. Soft starters are less costly than frequency converters at red. voltage
but like frequency converters, they may inject harmonic currents into the grid, disrupting other UM
processes. UM = Motor voltage
14
Typical motor current and torque curves
Current Torque
1 = Direct-On-Line starter
2 = Y/D-starter
3 = Start with soft starter
15
Starting time
Theory If only the starting torque and maximum torque of the motor and
the nature of the load are known, the starting time can be
The starting current of an induction motor is much higher than approximately calculated with the equation:
the rated current, and excessively long starting period causes K1
harmful temperature rise in the motor. The high current also Tst = (JM + JL) x
Tacc
leads to electro-mechanical stresses. It is, therefore, of
importance to know the time taken by the motor to accelerate where Tst = starting time
the load to rated speed. This time is called starting time or Tacc = acceleration torque as per diagrams, Nm
acceleration time. K1 = as per table below
TL x nL
TL' = nM
JL'=JL' x (nL/nM)2
16
Example of starting performance with different load torques
Example 1: Example 3:
Torque Torque
TL TL
Speed Speed
Example 2: Example 4:
TL TL
Speed Speed
17
Electrical braking
Countercurrent braking (Plugging) For slip-ring motors the starting and braking times are both
determined by the dimensioning of the rheostatic starter.
With countercurrent braking, an ordinary standard motor is
switched at full speed for the opposite direction of rotation. This
can be done with a reversing switch. After braking to a Torque Torque
standstill, the motor starts in the opposite direction of rotation,
unless the current is switched off at the right moment. A low
speed detector is therefore used to cut off the supply to the
motor when the speed approaches zero.
Torque Torque
where x = Permitted number of brakings per hour
P2 = Output taken from motor, kW
P1 = Rated output of motor in continuous duty, kW
tb = Braking time, s
Ist/I = Starting current / full load current
For squirrel cage motors the braking time can be calculated Braking torque Acceleration torque
approximately with the formula:
Although the load torque contributes to the braking torque, Speed detector with countercurrent braking
making allowance for it complicates the calculation unduly if the
braking time must be accurately known. It can therefore be said
A low speed detector designed to cut off the supply to the motor
that the braking torque is approximately equal to the
when the speed approaches zero can be used to terminate
acceleration torque, when the load current is approximately
countercurrent braking at the right instant. The speed detector
zero.
is usually mounted on the N-end of the motor and is driven from
the motor shaft via a coupling.
18
Direct-current braking Regenerative braking
When braking with this technique, the a.c. supply to the motor is This is the method of braking multi-speed motors when
disconnected and the stator is excited with direct current; this changing down to lower speeds. The thermal stresses are
causes the motor to produce a braking torque. approximately equal to those occuring when motors with dual
speed connections are started at lower rated speed. With the
An ordinary standard motor and suitable equipment for d.c. motor at the lower speed working as a generator, it develops
excitation may be used. The a.c. voltage follows a decay curve, very high braking torque in the interval between operating
and the d.c. voltage must not be connected until the a.c. voltage speeds of motor corresponding to the two poles. The maximum
has fallen to a value at which it will not harm the d.c. equipment. braking torque is slightly higher than the starting torque of the
motor at the lower speed. Regenerative braking is also used
The excitation current is determined by the braking time with variable speed drives.
chosen, but is usually 1 to 2 times the rated current of the
motor. However, saturation of the magnetic circuit imposes a Based on the thermal stesses developed during different
limit on the braking torque. braking methods, with reference to those developed during
direct-on-line starting, following thermal equivalence is drawn.
Direct-current braking gives a far longer braking time than
countercurrent braking, however high the excitation current, but Four jogs (or inching) = One start
thermal losses are lower, so more frequent braking is One DC injection braking = Two start
permissible. One plug stop = Three start
One regenerative braking = One start
If the d.c. voltage fails there will be no braking action. The
technique is therefore unsuitable for use in plants where loss of
braking could cause danger.
Time
Figure 3
(The lower curve shows the output voltage from the stator
winding of a small induction motor after disconnection from the
supply. Only half the curve is shown. The upper curve is a 50
Hz scale. With countercurrent braking, the d.c. voltage must not
be connected until the a.c. voltage has fallen to a value at which
it will not harm the d.c. equipment.)
Torque
Torque
Braking torque
Acceleration torque Mb
Torque
Figure 4
19
Duty types
The duty types are indicated by the symbols S1 ... S9 according to IS:12824-1989. The outputs given in the tables are based on
continuous running duty. S1 with rated output.
S1 P
Continuous running duty
N
Operation at constant load of sufficient duration for thermal
equilibrium to be reached. In the absence of any indication of
the rated duty type, continuous running duty will be assumed.
Designation: S1
Time
S2 P
Short-time duty N
Time
S3 P
Intermittent duty N R
Recommended values for the cyclic duration factor are 15, 25,
40 and 60%. The duration of the duty cycle is 10 min.
S4
Intermittent duty with starting P
A sequence of identical duty cycles, each cycle including a Period of one cycle
significant period of starting, a period of operation at constant
load and rest and de-energised period. The period is too short
for thermal equilibrium to be obtained. In this duty type the
motor is brought to rest by the load or by mechanical braking,
where the motor is not thermally loaded. After the duty type the
following factors must be indicated; the cyclic duration factor;
the number of duty cycles per hour (c/h); the factor of inertia FI;
Time
the moment of inertia, JM, of the motor rotor; and the permissible D N R
average moment of resistance, TV, during the change of the
speed given with the rated load torque. The factor inertia FI is
the ratio of the total moment of inertia, to the moment of inertia P = Output power V = Operation of no load
of the motor rotor. D = Starting R = At rest and de-energised
N = Operation under rated condition
Designation e.g. S4 - 25% - 129 c/h - FI.2 - JM = 0,1 kgm2 - TV = F = Electrical braking
0,5 TV.
20
S5
Intermittent duty with starting and electrical P
braking
Period of one cycle
A sequence of identical duty cycles, each cycle consisting of a
significant period of starting, a period of operation at constant
load, a period of rapid electric braking and a rest and de-
energised period. The period is too short for thermal equilibrium
to be obtained.
After the duty type the following factors must be indicated: the D Time
cyclic duration factor; the number of duty types per hour (c/h); the
factor of inertia FI; the moment of inertia JM, of the motor, and the F
permissible moment of resistance TV (see duty type S4.)
N R
Designation e.g. S5-40% -120 c/h- FI.3 - JM = 1,3 kgm2 - TV = 0,3 TN.
Period of one cycle
S6
Continuous-operation periodic duty
P
A sequence of identical duty cycles, each cycle consisting of a
period at constant load and period of operation at no load. The N
period is too short for thermal equilibrium to be obtained. V
Recommended values for the cyclic duration factor are 15, 25, 40
and 60%. The duration of the duty cycles is 10 min.
Time
Designation e.g. S6 40% P = Output power V = Operation of no load
D = Starting R = At rest and de-energised
N = Operation under rated condition
F = Electrical braking
S7 S8
Continuous-operation periodic duty with Continuous-operation periodic duty with related
electrical braking load speed changes
A sequence of identical duty cycles, each cycle consisting of a A sequence of identical duty cycles, each cycle consisting of a
period of starting, a period of operation at constant load and a period of starting, a period of operation at constant load
period of braking. Braking method is electrical braking e.g. corresponding to a predetermined speed of rotation, followed by
countercurrent braking. The period is too short for thermal one of more periods of operation at other constant loads
equilibrium to be obtained. corresponding to different speeds of rotation. The period is too
short for thermal equilibrium to be obtained. This duty type is
After the duty type the following factors must be indicated: the used for example by pole changing motors.
number of duty cycles per hour c/h, the factor of inertia FI: the
moment of inertia JM of the motor, and the permissible moment of After the duty type the following factors must be indicated; the
resistance TV ( See duty type S4) number of duty cycles per hour c/h; the factor of inertia FI; the
permissible average moment of resistance TV (see duty type S4);
Designation e.g. S7 40% - 500 c/h - FI.2 - JM = 0.08 kgm2 - TV = the cyclic duration factor for each speed of rotation and the
0,5 TN. moment of inertia JM of the motor.
Designation e.g.
21
Protection accessories
Motors subjected to atmospheric condensation, either through PTC thermistor is the most common type of temperature
standing idle on a damp environment or because of the wide detector. It is the characteristics of the thermistors that its
variation in the temperature of the surroundings, may be fitted resistance hardly varies with increasing temperature until the
with a heater for extra precaution. The heater ensures that the threshold temperature is reached, thereafter the resistance
temperature of the air inside the motor, is maintained a few increases sharply as shown in figure below. Thermistors must
degrees above that of the ambient to avoid any condensation. be connected to a separate control unit which trips power circuit
Such heaters shall not be kept ON when the motor is operating. when the resistance in the thermistor circuit increases abruptly.
These space heaters are generally rated for 240 V ac/dc.
Thermistors generally provided are rated for 130°C (PTC 130)
For motors not having the provision of space heaters, 24 V dc for class B rise and 155°C (PTC 155) for class F rise.
supply can be applied between any two terminals.
Normally three thermistors are provided in series - one
The leads of space heaters for frame 160 to 400 are terminated thermistor in each phase. Six nos. (three nos. for tripping and
in a separate auxiliary terminal box three nos. for alarm.) can be provided if intimated at the time of
enquiry.
Guide for fuse protection Like space heaters, the leads of thermistors for frame 160 to
400 are terminated in a separate auxiliary terminal box.
In addition to the starters being used to protect motors from
overload and under voltage, the motors are protected with fuse
as per the following table
0.37 1.2 6
0.55 1.6 6 4000
0.75 2.1 6
1.1 2.9 6
1.5 4.0 10 1330
2.2 5.7 16 10
3.7 8.3 16 16
4.0 9.5 25 16 550
5.5 12.2 25 16
7.5 15.5 25 25
9.3 19.4 32 25
11 22 32 25
15 29.5 50 50 100
18.5 37 63 50
22 42 63 63
30 52 80 63
37 66 100 80
45 80 125 100
55 98 160 125
75 128 200 160
90 155 225 200
110 188 250 200
132 223 315 250
160 270 355 300 Typical value _
200 332 400 350 Shaded area = tolerance limits
250 415 500 500
22
Voltage drop along the cable
Induction motors draw heavy currents during starting, resulting Determination of withstand capability
in considerable voltage drop along the cable, If other loads are
connected in parallel to the motors, the voltage drop along the Since the negative sequence currents result in overloading, the
common feeder causes operational problems to these amount of negative sequence current carried by the winding as
associated loads. Larger the starting current and longer the a percentage of rated current can be used as a measure of
common feeder, larger will be the voltage drop. In view of this overloading due to unbalance. The thermal withstand
while specifying motors or cables, it is required to estimate the characteristics of the machine available for different overload
right combination of starting current and cable size, alternatively, it conditions can be used to represent the capacity of the machine
is important to know voltage drop for an installation when to withstand negative sequence voltage and current. The
starting / locking of motors occurs such that the maximum negative sequence withstand characteristics are design specific
voltage drop is less than 3%. The relative voltage drop, D u is and will vary from motor to motor. A sample method for obtaining
estimated as negative sequence withstand characteristics of the motor is
Du = u- *100 given hereunder.
U
where, U is the rated voltage of the motor Sample calculation:
u is the voltage drop given as Let nominal voltage be 415 V and rated current be 60A.
Under unbalance condition let the voltages be
(
u = b rx L cosf + lLsinf Is
S
V = 385 L0° V
where u = Voltage drop V = 410 L120° V
b = Factor equal to 1 for three-phase circuits and V = 425 L 240° V
equal to 2 for single phase circuits
385 + 410 + 425
r = Resistivity of conductors in normal duty Average voltage = = 407V
taken as being equal to the resistivity at the 3
normal duty temperature, i.e. 1.25 times the Unbalance voltage = 425 - 407 x 100 = 4.42%
resistivity at 20°C, giving 0.02250 mm2/m for 407
copper and 0.0360mm2/m for aluminium Negative sequence voltage
L = Length of cabling in meters
385Ð0° + a2410Ð120° + a425Ð240°
S = Cross section of conductors in mm2 VN = =11.66Ð158° V
3
cosf = Power factor, if exact figure is not available it
is equal to 0.8 and sin~ = 0.6 % negative sequence voltage = 11.66 / 407 = 2.86% (appx. 3%)
l = Linear reactance of conductors, taken as
being equal to 0.08mQ/m if the exact figure Now if the parameters of the machine are as given below:
is not available R1 = 0.052
lS = Current in use R2 = 0.071
X1 = 0.51
X2 = 0.53
Negative sequence withstand characteristics s = 0.0123
then s1 = 2. 0.0123 = 1.9877
Negative sequence withstand characteristics are used to obtain
capability of the motor to withstand the overloading caused by From the equivalent circuit diagram
negative sequence currents that occur due to unbalance in VN
supply voltage. (R1+ R2 1s1)+ j(X1 + X2)
23
Power factor improvement chart
0.35 1.66 1.80 1.93 1.98 2.03 2.08 2.14 2.19 2.25 2.31 2.38
0.40 1.27 1.41 1.54 1.60 1.65 1.70 1.76 1.81 1.87 1.93 2.00
0.45 0.97 1.11 1.24 1.29 1.34 1.40 1.45 1.50 1.56 1.62 1.69
0.50 0.71 0.85 0.98 1.04 1.09 1.14 1.20 1.25 1.31 1.37 1.44
0.52 0.62 0.76 0.89 0.95 1.00 1.05 1.11 1.16 1.22 1.28 1.35
0.54 0.54 0.68 0.81 0.86 0.92 0.97 1.02 1.08 1.14 1.20 1.27
0.56 0.46 0.60 0.73 0.78 0.84 0.89 0.94 1.00 1.05 1.12 1.19
0.58 0.39 0.52 0.66 0.71 0.76 0.81 0.87 0.92 0.98 1.04 1.11
0.60 0.31 0.45 0.58 0.64 0.69 0.74 0.80 0.85 0.91 0.97 1.04
0.62 0.25 0.39 0.52 0.57 0.62 0.67 0.73 0.78 0.84 0.90 0.97
0.64 0.18 0.32 0.45 0.51 0.56 0.61 0.67 0.72 0.78 0.84 0.91
0.66 0.12 0.26 0.39 0.45 0.49 0.55 0.60 0.66 0.71 0.78 0.85
0.68 0.06 0.20 0.33 0.38 0.43 0.49 0.54 0.60 0.65 0.72 0.79
0.70 0.14 0.27 0.33 0.38 0.43 0.49 0.54 0.60 0.66 0.73
0.72 0.08 0.22 0.27 0.32 0.37 0.43 0.48 0.54 0.60 0.67
0.74 0.03 0.16 0.21 0.26 0.32 0.37 0.43 0.48 0.55 0.62
0.76 0.11 0.16 0.21 0.26 0.32 0.37 0.43 0.50 0.56
0.78 0.05 0.11 0.16 0.21 0.27 0.32 0.38 0.44 0.51
0.94 0.07
The power factor compensating capacitors are specified in terms of kVAR. The input kW of the motor is multiplied by the reading
to obtain the necessary improvement in the power factor.
Example - If the initial power factor = COSf1 =0.76
Input active power = 100 kW
Corrected power factor = COSf2 =0.90
From the chart: capacitor kVAR required per kW load = 0.37
hence
Total capacitor kVAR required = 0.37 x 100 = 37 kVAR
24
Mechanical
Motors in frame 71 to 315 have cast iron enclosures and larger As standard practice, the terminal box is located on the top of
ones have fabricated enclosures. Foot mounted motors have the motor. Extended side terminal box can be offered for frame
integrated feet. The housing and the end shields are machined 90 to 280. The terminal boxes for frames 71 to 280 are
to class tolerances to obtain perfect alignment and fits. rotatable in the steps of 900 and are made of die cast aluminum
alloy. For frames 225 and 400 the terminal boxes are rotatable
Core in steps of 900 and are made from cast iron. For all the terminal
boxes protection of enclosure of IP 55.
The stator and rotor cores of the motor are made of high quality
cold rolled non-grain oriented magnetic steel having low iron Motor upto 1.5 kW (2 hp) are provided with 3 terminal and
loss. others are provided with 6 terminals as standard practice. The
terminal plates and lead ferrules are marked U1, V1 and W1, of
U1, V1, W1 and U2, V2, W2. Terminal boxes have provision for
Protection against corrosion fixing cable glands to support copper or aluminum cables.
Special attention has been paid to the finish. Polyurethane paint Drain holes
is applied to motors. This provides an excellent finish and
protection against corrosion. The color of the paint is Munsell Motors for operation in very humid or wet environments, and
Blue. especially under intermittent duty, should be provided with drain
holes.
All the hardware are zinc passivated to give reliable anti-
corrosion protection under most server environmental HX Motors from frame HX 180 onwards are provided with drain
conditions. holes and closeable plastic drain plugs in the drain holes. The
plugs will be opened, on delivery. When mounting the motors, it
Winding and insulation should be ensured that the drain holes face downwards. In the
case of vertical mountings, the upper plug must be hammered
The insulation of the motors meet class F requirements home completely. In very dusty environments, both plugs
(temperature limit 155°C) the normal temperature however should be hammered home.
does not exceed the values permitted by class B (temperature
limit 130°C). The motors therefore have large overload margin
and long winding lifetime. If the temperature rise to class F is
allowed, the outputs given in the table can generally be
increased by approximately 12%.
Motor stators are wound with enamel wire and the winding is
then impregnated with solventless resin. The impregnation
effectively fills the gaps between conductors and makes the
winding mechanically strong, moisture and tropic proof.
The rotor cages of the motors upto 315 frames have die cast
construction whereas those of larger motors have fabricated
construction.
Earthing
Provision is given for earthing of motor. One earthing terminal
on terminal box and two earthing terminals on motor body are Open
provided.
25
Exploded view of HX motors
19
18
17
16
15
13
11
10 14
12
6
CD
A
M
RV
3 23
1 21
22
20
When the desired bearing life has been determined, the minimum Permissible radial forces
permissible pulley diameter can be calculated using FR' as follows: Motor sizes 71 to 132
7
D= 1.9 x 10 x K x P
n x FR
Length of Ball bearings
where: shaft
D = Diameter of pulley, mm Motor extension 20,000 hours
P = Power requirement, kW size Poles E (mm) X0(N) Xmax(N)
n = Motor speed, r/min
K = Belt tension factor, dependent on belt type 71 2 30 415 335
and type of duty. A common value for 4 30 415 335
V-belts is 2.5. 6 30 415 340
FR= Permissible radial force
80 M 2 40 670 545
4 40 890 725
Permissible loadings on shaft 6 40 970 830
The tables below give the permissible radial force in newtons, 90 SL 2 50 795 625
assuming zero axial force. The values are based on normal 4 50 995 780
conditions at 50Hz and calculated bearing lives for motor sizes 71 6 50 1135 880
to 132 of 20000 hours and for motor sizes 160 to 400 of 20,000 and
40,000 hours. 100 2 60 1090 875
4 60 1360 1095
Motors are foot-mounted 1MB3 version with force directed 6 60 1560 1250
sideways. In some cases the strength of the shaft affects the
permissible forces. 112 2 60 1410 1120
4 60 1735 1400
At 60Hz the values must be reduced by 10%. For two - speed 6 60 2000 1620
motors, the values must be based on the higher speed.
132 SM 2 80 1700 1330
Permissible loads of simultaneous radial and axial forces will be 4 80 2130 1660
supplied on request. 6 80 2495 1935
FR
X
Xmax X0
27
Permissible radial forces
160 2 110 2980 2310 2350 1810 5530 4260 4370 3360
4 110 3760 2900 2970 2290 6980 5380 5520 4250
6 110 4290 3300 3390 2750 7980 6150 6310 4860
8 110 4730 3660 3740 2880 8800 6780 6960 5360
180 2 110 3540 2880 2790 2260 6260 5080 4940 4010
4 110 4390 3560 3440 2790 7830 6350 6160 5000
6 110 5060 4110 3970 3220 9000 7300 7100 5750
8 110 5590 4540 4390 3560 9940 8060 7830 6350
200 ML 2 110 4510 3700 3530 2900 8520 7000 6710 5510
4 110 5660 4650 4430 3640 10710 8800 8440 6930
6 110 6470 5310 5050 4150 12250 10060 9640 7920
8 110 7160 5880 5600 5880 13520 11100 10650 8750
225 SM 2 110 4750 4010 3710 3130 9720 8200 7650 6450
4 140 6310 5040 4920 3840 12900 10310 10150 8120
6 140 7200 5760 5620 4500 14740 11800 11600 9280
8 140 7970 6375 6230 4980 16270 13010 12820 10250
250 SM 2 140 6100 4910 4750 3830 13600 10960 10710 8640
4 140 7650 6170 5960 5450 17100 13800 13470 10870
6 140 8700 7010 6760 5450 19520 15740 15360 12400
8 140 9630 7760 7505 6050 21550 17380 16970 13690
280 SM 2 140 7300 6200 5800 4900 20200 6600 16500 6600
4 140 9200 7800 7300 6200 25000 12000 20300 12000
6 140 10600 8900 8400 7100 28000 12000 23000 12000
8 140 11600 9800 9200 7800 30700 12000 25000 12000
315 SML 2 140 7300 6000 5800 4950 20200 6350 16500 6350
4 170 11300 9400 9000 7500 32500 10700 26500 10700
6 170 13000 10600 10300 8500 37000 10600 30000 10600
8 170 14300 10400 11300 9400 40000 10400 32700 10400
355 SM 2 140 9000 7900 6100 5300 26700 8900 21800 8900
4 210 15200 12500 12000 9850 45000 21400 36700 21300
6 210 17300 14300 13700 11300 51000 21100 41500 21100
8 210 19000 15700 15200 12400 55500 21700 45200 21700
355 ML 2 140 9100 7100 6100 5400 26900 7100 21800 7100
4 210 15200 12800 12000 10100 45500 19500 36700 19500
6 210 17300 14600 13700 11500 51000 19000 41500 19000
8 210 19300 16200 15200 12700 55500 19500 45200 19500
400 L 2 140 8900 3000 5700 3000 27000 3000 22000 3000
4 210 15000 13000 11700 10100 46000 15000 37000 15000
6 210 17200 13700 13600 11700 52000 13700 42000 13700
8 210 19200 15000 15000 12900 55500 15000 46000 15000
28
Permissible axial forces
The following tables give the permissible axial forces in newton, For two-speed motors, the values are to be based on the higher
assuming zero radial force. The values are based on normal speed. The permissible loads of simultaneous radial and axial
conditions at 50Hz with standard bearings and calculated forces will be supplied on request.
bearing lives of 20,000 and 40,000 hours.
Given axial forces FAD' assumes D-bearing locked by means of
At 60 Hz the values are to be reduced by 10%. locking ring.
FAD FAZ
Mounting arrangement 1M83
FAZ
160 2420 1820 3040 2280 3480 2600 3810 2920 1970 1370 2480 1720 2840 1960 3090 2200
180 2860 2100 3690 2450 4160 2920 4530 3290 2300 1570 3050 1810 3400 2160 3690 2450
200 3600 2500 4580 3120 5280 3530 5720 3980 2970 1870 3780 2320 4370 2620 4720 2980
225 4140 2740 5230 3440 6030 3900 6530 4400 3430 2030 4330 2550 5010 2870 5400 3270
250 5020 3330 6380 4150 7440 4610 8050 5210 4160 2470 5290 3060 6200 3360 6680 3840
280 8500 4300 9500 4600 11000 5500 12200 6600 6950 2700 7700 2800 8900 3350 9750 4200
315 SML 9000 3700 11600 5400 13500 6200 14500 7500 7450 2100 9450 3200 10900 3650 11900 4650
355 SM 14900 800 19200 3100 22200 4100 24000 5800 13000 1) 16400 1) 18900 850 20300 2100
355 ML 15000 1) 19800 1700 23100 2500 25000 4300 13100 1) 17000 1) 19800 1) 21300 1)
400 L 17300 1) 21800 1) 24300 1000 26200 2500 15400 1) 18900 1) 21100 1) 22500 1)
1) On request
29
Testing
The standard test programmes are dividing into four parts: Type test
routine tests, type tests, optional tests and special tests. The
routine test program is done to every machine. Type test is 1. Dimensions
performed in addition to routine tests normally to one of the 2. Measurement of resistance of stator
machines of a series of similar machines or by a request of the
3. Locked rotor test
customer. Optional tests are additional type tests subject to
mutual agreement between purchases and the manufacturer. 4. Temperature rise test
Special tests are needed if the machine has to run in special 5. Full load test
conditions e.g. roller table, hazardous areas, cranes 6. No load test at rated voltage
applications. The special test program is specified by the 7. Reduced voltage running test
customer/consultant/standards bureaus. 8. Momentary overload test
9. Insulation resistance test
If the motor will be fed by a frequency converter it is most often 10. High voltage test
tested together with the frequency converter.
Optional tests
Unless otherwise specified all the tests are performed
according to standard IS:325-1996.
1. Vibration severity test
2. Sound level measurement
Contents of test programmes: 3. Degree of protection test
4. Temperature rise test at limiting values of voltage and
Routine tests frequency variation
5. Over speed test
1. Insulation resistance test 6. Test on insulation system
2. Measurement of resistance of the stator
3. Locked rotor test Special tests
4. No load test
5. Reduced voltage running test 1. Acceleration constant test (B value test, for roller table
6. High voltage test motors)
2. tE time test (for increased safety motors)
3. Suitability to PWM supply
30
Motors for frequency converter drive
Squirrel cage induction motors offer excellent availability, At low speed operation the motor's ventilation fan loses its cooling
reliability and efficiency. In addition to that, a motor with a capacity, which causes a higher temperature rise in the motor
frequency converter - variable speed drive (VSD) - has even more and bearings. A separate constant speed fan can be used to
excellent properties. A variable speed drive motor can be started increase cooling capacity and loadability at low speed. It also
softly with low starting current, and the speed can be controlled important to check the performance of the grease at low speeds.
and adjusted to suit the application demand without steps over a
wide range. Also the use of a frequency converter together with a 3. Lubrication
squirrel cage motor usually leads to remarkable energy savings.
Most of the squirrel cage motors manufactured by ABB are The effectiveness of the motor lubrication should be checked by
suitable for variable speed use, but in addition to the general measuring the bearing temperature under normal operating
selection criteria, the following points must be taken into account: conditions. If the measured temperature is higher than + 80°C, the
relubrication intervals specified in ABB' s standard instruction
manuals must be shortened; i.e. the relubrication interval should
1. Dimensioning be halved for every 15K increase in bearing temperature. If this is
not possible ABB recommends the use of lubricants suitable for
The voltage (or current) fed by the frequency converter is not high operating temperature conditions. These lubricants allow
purely sinusoidal. This may increase the losses, vibration, and normal relubrication interval and a 15K increase in bearing
noise of the motor. Furthermore, a change in the distribution of the temperature conditions.
losses may affect the motor temperature balance and lead to an
increase in the temperature of the bearings. In every case, the 4. Insulation protection
motor must be correctly sized according to the instructions
supplied with the selected frequency converter.
If the frequency converter has IGBT power components with very
When using ABB converters use the Drive Size dimensioning rapid switching, practically all cables between the converter and
program or "ISOTHERM GUIDE-LINES" of the corresponding the motor will be long. In that case, steep voltage pulses and
converter type for sizing the motors. The loadability curve of a reflections at the cables increase voltage stresses at the winding
standard motor used with a ACS 600-frequency converter can be of the motor and therefore, the precautions described in figure 2
found from figure 3. below must betaken to avoid risks of insulation damage.
For higher speeds, ensure that the highest permissible rotational Bearing voltages and currents must be avoided in all motors.
speed of the motor or the critical speed of the entire equipment is When using an IGBT frequency converter insulated bearings
not exceeded. When high speed operation exceeds the nominal and/or a properly dimensioned filter at the converter output must
speed of the motor, the following points should be checked: be used according to instructions in figure 2 below. (For other
alternatives and converter types, please contact ABB.) When
• Maximum torque of the motor ordering clearly state which alternative will be used.
• Bearing construction
• Lubrication For more information about bearing currents and voltages, please
• Balancing contact ABB.
• Critical speeds
• Shaft seals 6. Cabling, grounding and EMC
• Ventilation
• Fan noise The use of a frequency converter causes some extra
requirements on the cabling and grounding of the drive system.
Permissible maximum speeds for standard motors are described The motor must be cabled by using shielded symmetrical cables
in figure 1. and cable glands providing a 360º bonding (also called EMC-
glands). For motors up to 30 kW unsymmetrical cables can be
Figure 1. used, but shielded cables are always recommended.
Maximum permissible speeds for basic motors
For motor frame size 280 and upward, additional potential
Frame size Speed r/min equalisation between the motor frame and the machinery is
2-pole 4 -pole needed, unless they are installed on a common steel fundament.
When a steel fundament is used for the potential equalisation, the
71 - 200 4000 3600 high frequency conductivity of this connection should be checked.
225 - 280 3600 2600
315 3600 2300 More information about grounding and cabling of a variable speed
355 3600 2200 drive can be found from the manual "Grounding and cabling of the
400 3600 1800 drive system" (Code: 3AFY 61201998RO125REVA)
31
For fulfilling the EMC requirements, special EMC cable(s) must be used in addition to the correct cable gland mounting, with special,
extra earthing pieces. Please refer to the manuals of the frequency converter.
Figure 2. Selection rule for insulation and filtering in variable speed drives
Series reactor. dU/dt filters decrease the changing rate of the The loadability curve in figure 3 below is a guide line curve, for exact
phase and main voltages and thus reduce voltage stresses in values please contact ABB.
the windings. dU/dt filters also decrease so called common
mode currents and bearing currents. These guidelines present the maximum continuous load torque of a
motor as a function of frequency (speed) to give the same temperature
Common mode and light common mode filters rise as with rated sinusoidal supply at nominal frequency and full rated
load.
Common mode filters are made of toroidal cores installed
around motor cables. These filters reduce so called common The temperature rise of squirrel cage motors manufactured by ABB is
mode currents in VSD applications and thus decrease the risk normally class B. If the ABB catalogue indicates that class F
of bearing currents. Common mode filters do not significantly temperature rise is utilised on a sinusoidal supply, the dimensioning of
affect the phase or main voltages on the motor terminals. For the motor at frequency converter supply should be done according to
the exact type of the core, please contact ABB. the temperature rise class B loadability curve
Common Mode Filter = 3 toroidal cores per each 3-phase motor For further information, please contact ABB. .
cable
Light Common Mode Filter = 1 toroidal core per each 3-phase
motor cable
Figure 3. Motor loadability with ACS 600, Field weakening point 50Hz.
32
Guide and check points for motor selection
(mechanical aspects)
Totally enclosed
fan cooled Ventilation
Separately cooled
Natural cooled
Standard
Double shaft Shaft end Power Transmission Direct
Tapered Belt
Special Gear box
Mounting Foot
Horizontal Installation Flange
Vertical Face
Dimension IS/IEC
User specific
Noise Standard
Low
Standard Vibration
Precision
Bearings Ball
Roller
33
Guide and check points for motor selection
(electrical aspects)
Equivalent starts
per hour
Frequency 50 Hz
Mechanical Braking
Plugging
DC injection
Regenerative
Torque
Characteristics Normal starting
High torque
Soft starting (Low pull out torque)
B/F Temperature
F/F rise / insulation
F/H
Determination
of motor
specification
34
Ordering Information
36
Frequency asked questions
Q. What are the general performance concerns of Q. What is the normal value of no-load current?
motor?
There is no standard value of no-load current. It depends on the
Rated current, speed, starting current, starting torque, efficiency, design philosophies and manufacturing practices. This parameter
power factor, noise and vibration. Above all is the temperature rise is in-fact manufacturer specific and its value varies widely from
of the motor in accordance with operating environment and class manufacturer to manufacturer. Further, pole number and size of
of insulation. motor greatly influence values of no-load current. Value of no-load
current can vary from 20% of full load current for 4 pole motors to
Q. Why is the consideration for efficiency growing ? 80% for 8 pole motor. Similarly, in smaller motors the value of no-
load current as a percentage of full load current is much higher as
compared to larger motors. In smaller motors of higher pole
Higher efficiency means lower kW power drawn from electric numbers, there are cases where no-load current is higher than full
supply and hence, lower electricity bills. Further, energy efficient load current.
operation has been a top social obligation from an environmental
and global viewpoint.
Q. How is no-load current related to the design
Q. How are efficiency and power factor philosophy?
correlated?
Since EBDs use magnetic circuit more optimally than electric
circuit, the magnetising current could be higher as compared to
Due to continuous innovations made in the designs of motors, PFBDs. This could lead to higher no-load current in EBD designs.
over the years, values of efficiency and power factor in standard
motors have reached an optimum level. Thus here onwards,
unless an entirely new series of motors are made, improvement in Q. Is there any adverse effect of higher no-load
one adversely affects other. That is, in standard motors, an current on the motor?
attempt to improve efficiency normally results in lower power
factor and vice-versa. No, if the motor is designed for higher no-load current, it would
have no effect on its declared performance and life.
Q. What is efficiency based design (EBD) and
what is power factor based design (PFBD) ? Q. Does higher no-load current design affect
other performance parameters?
Around the world, in standard series motors, there are two design
philosophies. One is called "Efficiency Based Design (EBD)" and Only in a few cases, the rated current of EBD motors could be
the other is called "Power Factor Based Design (PFBD)". In the slightly higher than that of PFBD motors. Since the motor is
former case, the basic design including stamping designs are designed for the rated current, declared performance is
optimised for maximising efficiency, while retaining power factor guaranteed. But in terms of input kW, EBD motors would result in
to reasonably acceptable level. Where as in the latter case, it is lower electricity bills. After all it must be understood that no-
otherwise. load current is a quality control parameter and not a
performance parameter.
Q. What is the difference in electromagnetic
parameters in case of the above two designs? Q. Why EBDs are more popular than PFBDs ?
EBDs are based on lower losses and hence lower resistances. Both efficiency and power factor can be built into the motor. But
Lower resistance in the circuit could lead to lower power factor. once the motor is built, efficiency can not be improved by external
Where as PFBDs have higher rotor resistances. measures, though, power factor can be improved by using
capacitors. Hence, the usual practice is to maximise the motor
efficiency at design stage and improve power factor at operational
Q. How EBDs and PFBDs compare on other stage i.e. by capacitors. A case study of benefits in energy saving
performance parameters? by employing EBD motor is illustrated below for 3 number 30kW
/4pole motors in a pump application.
Since EBDs have lower rotor resistances, the starting torque
could be lower. To compensate this, flux level might go up leading
to higher magnetic current. Parameter PFBD EBD
motor motor
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