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Product portfolio

BU LV Motors
Process Performance General Performance
M3BP 71-450, IE2, IE3, IE4
M3AA 71-280, IE2, IE3
M2BA 71-355, IE1, IE2
M2AA 56 250, IE1, IE2
Other applications
Motors for explosives atmospheres
Marine motors
Water cooled motors
Brake motors
Smoke extraction motors
Roller table motors
Permanent magnet motors
Synchronous reluctance motors
IEC Low voltage motors
Aluminium
Cast Iron
Motors for high ambient temperatures
Traction induction motors
Traction synchronous motors
BU LV Motors Product portfolio
IE class defined in the IEC/EN 60034-30 and IEC/TS
60034-31
IE efficiency classes for 50 Hz 4-pole motors
IEC/EN 60034-30
Covered in both:
Single-speed, three-phase
2, 4 and 6-pole
Rated output from 0.75 to 375 kW
Determination of total losses with P
LL
determined from residual losses
Excluded from IEC/EN 60034-30:
Motors made solely for converter
operations in accordance with IEC 60034-
25
Motors completely integrated into a
machine that cannot be tested separately
from the machine
Excluded from Regulation (EC) No 640/2009
of 22 July 2009 (in addition to IEC/EN 60034-
30) :
Motors designed for use in potentially
explosive atmospheres as defined in ATEX
Directive 94/9/EC
Brake motors
Motors designed for ambient air
temperature outside range (-15C..+40C)
Motors designed for altitudes exceeding
1000m above sea level
Motors designed for temperatures above
400C
Efficiency, definition
Efficiency is ratio between mechanical output
and electrical input
High efficiency means that the motor is
converting electrical power to mechanical
power with small losses
U I P cos
P
Output
rpm
load
P
Input
Losses
P

P
Output

Input
P

P
Output
P
Losses
P
Output
+
P
Input

P
Input
P
Losses
Energy supply
P
input
= Electrical power input
P
output
= Mechanical power
output
P
friction & windage
P
output
P
LL
P
winding
P
input
P
iron
P
rotor
Stator winding losses (P
ws
)
Rotor losses (P
wr
)
Iron losses (P
fe
)
Additional load losses (P
LL
)
Additional load losses are due to:
Friction + Windage losses (P
fw
)
leakage flux, mechanical imperfections
in the air gap and irregularities in the
air gap flux density
Losses split into five major areas
Losses and efficiency in electrical motors
Electrical
energy in
(P
in
)
Mechanical
energy out
(P
out
)
P
cu1
35 %
Stator winding
P
cu2
20 %
Rotor winding
P
Fe
20%
Iron
P
Fr
Friction 10 %
P
LL
15 %
Additional
P
out
94 %
Mechanical
energy out
Losses 6 %
P
out

P
in
= 100 x
[%]
IEC low voltage motors
Process performance motors
High efficiency IE2;
aluminum and cast iron
Premium efficiency IE3
Super premium
efficiency IE4
General performance motors
High efficiency IE2;
aluminum, steel and
cast iron
Output power in kW
01 MW
75 355 kW
0.12 1000 kW
0.12 630 kW
11 355 kW
Process performance motors
IE2 High efficiency motors
Motors for the most demanding
continuous process applications
Tailor-made to meet the individual
needs of applications
Fulfilling IE2 efficiency class, available
from stock
3 years warranty, option for 5 years
Output 0.25 kW to 1 MW
Type M3BP / M3AA
Frame sizes 71 to 450 in cast iron
63 to 280 in aluminum
Process performance motors
IE3 Premium efficiency motors
Motors for the most demanding
continuous process applications
Tailor-made to meet the individual
needs of applications
Fulfilling IE3 efficiency class, available
from stock
Output 11 to 375 kW
Type M3BP
Frame sizes 160 to 355
Cast iron
*) renaming from M4BP during 2011
Process performance motors
IE4 Super premium efficiency motors
Motors for the most demanding
continuous process applications
Tailor-made to meet the individual
needs of applications
Fulfilling IE4 efficiency class
Continuous development for future
needs of efficiency
Output 75 to 375 kW
Type M3BP
Frame sizes 280 to 355
Cast iron
General performance motors
IE2 High efficiency motors
Standard motors, targeted at new high
volume serial OEMs
Off-the-shelf availability
On-line documentation
IE2 efficiency class
1 year warranty
Product types:
Output 0.06 to 630 kW
Type M2BA / M2BAT /
M2AA / M2CA
Frame sizes 71 to 355 in cast iron
56 to 250 in aluminum
280 to 400 in steel
*) availability to be checked for sizes
up to 132
Key to success
Losses
Elimination of rotor losses
I
2
R
Stator
I
2
R
Rotor
Other
I
2
R
Stator
Other
I
2
R
Stator
Other
IE2 induction motor
IE4 SynRM motor
High Output SynRM motor
100%
60%
80 -90%
Two new innovative motor-drive packages
The technology for variable speed applications
Standard
motor
+
special rotor
Standard drive
+
new software
SynRM
motor-drive
package
The IE4 SynRM package
Energy losses reduced by up to 40% compared to IE2 efficiency class
Interchangeable with IE2 induction motor without costly mechanical
modifications
The High Output SynRM package
Powerful, yet highly compact motor with up to two frame sizes smaller
than conventional induction motor without compromising efficiency
Lighter and smaller motors enable cost effective machine designs
Both packages are based on perfectly controlled synchronous
reluctance motor (SynRM) technology without permanent magnet
materials. Optimized for VSD operation, they combine motor, drive and
advanced software into complete solutions.
Trademark and name
Motor characteristics
Cast iron motor frame M3BL 160 - 315
Generation code C in product code
Variant codes and mechanical construction details based on
mother product M3BP
Drive characteristics
New ABB Drives product ranges support the synchronous
reluctance control software. The first family with the
revolutionary software is ACS850.
Supply voltage 3-phase 380 V to 500 V, 50 Hz and 60 Hz
ABBs Direct torque control (IM, PM or SynRM)
New option code +N7502 SynRM control firmware (not
included in ACS850 as standard)
IE4 / HO SynRM motor and ACS850 drive package
Compact High output SynRM vs. IE2 IM package
What does smaller size mean in practice?
3000 rpm comparison same power
Upper motor HO SynRM, lower motor traditional induction
motor
Package efficiency difference between HO SynRM and IE2
induction motor-drive package
Motors for explosive atmospheres
IE2 Flameproof motors
Ex d and Ex de
Increased safety motors
Ex e
IE2 Non-sparking motors
Ex nA,
aluminum and cast iron
IE3 Non-sparking motors
Ex nA,
aluminum and cast iron
Dust ignition proof motors
Ex tD,
aluminum and cast iron
Output power
0.12 1000 kW
75 355 kW
0.25 390 kW
0.55 950 kW
01 MW
0.55 750 kW
Worker Protection Directive 1999/92/EC
Zones
Determination of Zone
Presence of explosive atmosphere:
Zone 0/20
continuously or for long periods or
frequently
Zone 1/21
in normal operation occasionally
Zone 2/22
not in normal operation, but if it does
occur, will persist for a short period
only
Combinations for G and D are possible
Zone 2 (G) / 22 (D)
Abnormal condition
Presence of explosive atmosphere
only by accident, but not during
normal duty ( 10 h per year)
Zone 1(G) / 21 (D)
Occasionally
Incidental presence of explosive
atmosphere during normal duty
(10 to 1000 h per year)
Zone 0 (G) / 20 (D)
Continuously
Permanent presence of
explosive atmosphere
(> 1000 h per year)
Product Directive 94/9/EC
Equivalence of Zones and product/equipment Categories
Zone 0 or 20:
Category 1 equipment can be used
no motors can be installed
Zone 1 or 21:
Category 1 and 2 equipment can be used
motors must be e, p, d or
tD A21
Zone 2 or 22:
Category 1, 2 and 3 equipment can be used
motors must be at least nA, p or
tD A22
Zone 2 (G) / 22 (D)
Abnormal condition
Presence of explosive atmosphere
only by accident, but not during
normal duty ( 10 h per year)
Zone 1(G) / 21 (D)
Occasionally
Incidental presence of explosive
atmosphere during normal duty
(10 to 1000 h per year)
Zone 0 (G) / 20 (D)
Continuously
Permanent presence of
explosive atmosphere
(> 1000 h per year)
Category 1
Category 1 or 2
Category 1, 2 or 3
Risks associated with explosive atmospheres
Effects of an AC drive on the motor
When controlling motors in potentially explosive
atmospheres, it is important to be aware of the
effects an AC drive has on the motor
The effect of an AC drive on the operating
conditions of a motor changes, compared to
direct-on-line (DOL) operation due to:
Higher voltage stress due to steep
voltage pulses
Common mode voltages and currents
Higher motor surface temperature rise
due to non-sinusoidal supply
For these reasons, Worker Protection and
Product Directives call for extra attention
to be given when an Ex motor is used with
an AC drive.
Risks associated with explosive atmospheres
Sparks and excess temperature
Electric motor installed in potentially explosive
atmosphere and operated with
AC drive increases risk of explosion through:
Sparks in motor windings due to insulation
breakdown caused by steep voltage rises
and reflected voltages
Sparks in motor bearings due to common
mode voltages caused by
AC drive
Increase in motor surface temperature
resulting in reduced cooling capacity or
overload of the motor
ABB Group
April 19, 2013 | Slide 21
Risks associated with explosive atmospheres
Protection against ignition from sparks in motor windings
Steep voltage pulses stress stator winding
insulation causing insulation breakdown
Reflected voltage pulses increase voltage stress
Reflected voltages can increase motor terminal
volts by 2.5 times nominal voltage
500 and 600 V motor needs either reinforced
insulation or drive requires du/dt filters
Above 600 V reinforced insulation and
du/dt filters are needed
Total accumulated voltage
Original voltage pulse
Reflected voltage pulse
Risks associated with explosive atmospheres
Protection against ignition from sparks in motor bearings
AC drive can cause common mode voltages
which induces voltages across motor bearings,
leading to current flow through motor bearings
Results in premature bearing failure with sparks
risk, which could cause ignition
To reduce risk of ignition and prolong bearing
life:
IEC 280 frame motors and above need
insulated non-drive end bearings to break
circulating currents paths
IEC 355 frame motors and above need
additionally common mode filter in AC drive
Risks associated with explosive atmospheres
Protection against excess motor surface temperature
High motor surface temperatures may be
caused by running motor at reduced speed,
harmonics caused by the converter or excess
load.
With shaft mounted cooling fan, reduced speed
will reduce the cooling capacity
For use in explosive atmosphere locations,
motor surface temperature must be rigorously
tested in accordance with appropriate standards
T1 T2 T3 T4 T5 T6
450 C 300 C 200 C 135 C 100 C 85 C
Risks associated with explosive atmospheres
Protection against excess motor surface temperature
Protection methods for ensuring correct motor
surface temperature depend on the protection
type of the motor
AC drive can act as a thermal protective device
Key is to ensure that essential surface
temperature stays below allowed limits by:
Direct temperature measurement
Controlling and limiting the power which is
transferred to the motor
Self-cooled motors
Motors with separate
cooling
The route to EC Declaration of Conformity
ABB drive with DTC (direct torque control)
If the motor voltage is 500 V
If the motor voltage is 500 to 600 V
If the motor voltage is 600 to 690 V
Check the frame size:
Up to IEC 250...
IEC 280 to 315...
IEC 355 and above...
... a standard motor is ok
... insulated non-drive end
bearings
... insulated non-drive end
bearings
... common mode filtering
installed
Up to IEC 250...
IEC 280 to 315...
IEC 355 and above...
... if a du/dt filter is
selected for the drive
(as above) a standard
motor is ok
... insulated non-drive end
bearings
... insulated non-drive end
bearings
... common mode filtering
installed
Motor needs
reinforced winding
insulation
AC drive needs
du/dt filtering fitted
motor
needs
motor
needs
AC drive
needs
OR
motor
needs
AC drive
needs
motor
needs
motor
needs
AC drive
needs
AND
motor
needs
In addition, check the frame size.
Motor needs
reinforced winding
insulation
AC drive needs
du/dt filtering fitted
In addition, check the frame size.
Up to IEC 250...
IEC 280 to 315...
IEC 355 and above...
... no additional motor or
drive requirements
other than those above
... insulated non-drive
end bearings
... insulated non-drive
end bearings
... common mode filtering
installed
Ex nA
ABB industrial drive
with DTC, ACS800
Ex t/Ex tD/DIP
Ex d
Ex de
EC Declaration
of Conformity
Important note 1: This flowchart only applies to ABBs low voltage
random-wound motors for explosive atmospheres.
Important note 2: This flowchart does not apply to ACS850 drives.
DriveSize
- Using ABBs DriveSize tool,
users can select a suitable
combination of motor and drive.
Web site
- Contains all relevant certificates
for tested drive and motor
combinations.
www.abb.com/drives
www.abb.com/motors&generators
Easy selection of motors for VSD suply
Easy to use table for selection of winding insulation, filters and insulated
bearings
Motor nominal power PN or frame size
P
N
< 100 kW P
N
100 kW or P
N
350 kW or
IEC 315 IEC 400
U
N
500 V Standard motor Standard motor Standard motor
+ Insulated N-bearing + Insulated N-bearing
+ Common mode filter
U
N
600 V Standard motor Standard motor Standard motor
+ dU/dt - filter + dU/dt filter + Insulated N-bearing
+ Insulated N-bearing + dU/dt -filter
OR OR + Common mode filter
Reinforced insulation Reinforced insulation OR
+ Insulated N-bearing Reinforced insulation
+ Insulated N-bearing
+ Common mode filter
U
N
690 V Reinforced insulation Reinforced insulation Reinforced insulation
+ dU/dt - filter + dU/dt - filter + Insulated N-bearing
+ Insulated N-bearing + dU/dt -filter
+ Common mode filter
Measures in above mentioned apply to process performance motors
with ACS550 and ACS800 drives with uncontrolled DC-voltage. For
other alternatives and converter types, please contact ABB.
High voltage cast iron motors
Product presentation
High voltage cast iron motors
Wide product range
Product strategy: HXR engineered motor
M3BM standard catalogue product U / V
Frame size
1 kV
280 400 450
6,6 kV
315 355 500 560
10 kV
M3BM
(HV)
3 kV
M3BP (LV)
HXR
High voltage Process performance cast iron motor
Product range
M3BM
110 - 750 kW at 50 Hz
150 - 950 HP (SF 1.15) at 60 Hz
2.3 - 10.0 kV
Shaft heights:
IEC 315 450
NEMA 506AT 728
50/60 Hz
2 to 8 poles
IM 1001, IM 3011, IM 2001
IC 411 / IP 55
Horizontal, vertical, foot & flange
IEC, NEMA, CSA
IEC
NEMA
High voltage cast iron motors, HXR
Wide range of designs
100 - 2250 kW at 50 Hz
150 - 3000 HP at 60 Hz
Low voltage to high voltage up to 11.5 kV
Shaft heights:
355 mm - 560 mm 14.5 '' - 22 ''
Horizontal or vertical
IEC, NEMA, CSA
HV Modular induction motors
General
Comprehensive range of motors ranging
up to 15 kV and 23 000 kW / 31 000 HP
Motor types AMI
Shaft heights 400 to 1000 mm
Poles 2 to 20
50 and 60 Hz
Ambient -50C to +60C
Ambient -58F to +140F
Suitable for IEC and NEMA standards
Motors for safe and hazardous areas
Motors for onshore and offshore
applications
Horizontally or vertically mounted
Motor intended for explosive
atmosphere
Protection category acc. to EN/IEC
Flameproof Ex d, Ex de
Totally enclosed, fan cooled
Cooling methods: IC411 and IC511
Both cast iron and welded steel frame
available
Certified according to ATEX Directives,
IEC, EN and NEMA standards and all
major local requirements

Suitable for variable speed drives


Power: 160 8,000 kW
Frame sizes: 355 900
PG Large AC Motor product offering
Flameproof motors Ex d
Slip ring unit located separately at the
end of the motor to allow easy
maintenance
Can be equipped with permanent
contact brushes
Suitable for variable speed drives or
with a brush lifting device for continuous
running
Power: 300 18,000 kW
Frame sizes: 400 1120
PG Large AC Motor product offering
Slip-ring motors
ABB synchronous motor modular product
platforms cover:
From small to large power:
1 - 65 MW
1 300 - 87 000 HP
From slow to full speed: 20 - 2000 rpm (also
2 pole available)
From small to large size:
Shaft height 0710 - 2500 mm
From medium to very high voltages:
1 - 60 kV
Endshield and pedestal mounted, horizontal
and vertical design
All main cooling types
Motor design for hazardous environment
according to main Ex standards
All main DOL starting methods and VSD
technology supported
PG Large AC Motor product offering
Synchronous motors
A motor is only as good as its
consistent parts
More than half of the price
is material
In critical applications with high
downtime costs every minute
of trouble free operation counts
Quality is reliability
Looking at the big picture
Moving the focus to decades of use
Energy 97%
One
rewind 1%
Initial
purchase 2%
BU LV Motors
Energy facts about LV motors
Loss
6.4 kW
Losses at 92.1 %
Loss
3.8 kW
Losses at 95.1 %
Reduced losses = 2.6 kW
Savings 1251 EUR per year = 11 tonnes CO
2 (0,5kg/kwh)
81.4 kW
75 kW
If the efficiency level increases with 3 %-units, the reduction of losses is 40%
78.8 kW
BU LV Motors
ABB pilot test motor - Petrom
The measured values (average 24h consumption, JUN
AUG 2009) were the following:
Old motor 165kWh & 133kVARh (PF = 0.778)
The measured values (average 24h consumption starting
from AUG 2009) were the following:
ABB motor 156kWh & 96kVARh (PF = 0.851)
Based on the above, the following results can be noted:
efficiency increase of at least 5.5%
network power factor improvement from 0.78 to 0.85
estimated money saving of 540EUR/year
no breakdown since ABB motor was installed
no visible signs of deterioration after 4 month
The maximum efficiency gain of 8.5% can be achieved if the motor works at
nominal load.
Considering the energy price of 0.05EUR/kWh