High Voltage Cast Iron Motors, HXR

Up to 2250 kW, 3000 HP

 ABB, your multi-domestic partner

ABB manufactures, markets and sells

electric drives and has over 100 years
experience in applying high voltage AC
motors and generators to virtually all
industries.

Our continuous research and development

program ensures our motors utilize the
latest technology and materials to provide
improved performance and reliability.
ABB is committed to maintaining this
technological edge both now and in the
future.

Our extensive and long experience

combined with our resources and global
multi-domestic sales and service functions
make ABB the first choice as an AC motors
and generators supplier.

Each motor is custom designed to meet

your specific applications. When you need
dependable, high efficiency AC motor
power, you can rely on the innovative
HXR series of totally enclosed fan cooled
motors and generators from ABB.

2 ABB
HXR, the motor for many applications

Standard range
• Totally enclosed fan cooled cast iron construction HXR Output at 6000 V 50 Hz
• 100 to 2250 kW at 50 Hz 2000
• 150 to 3000 HP at 60 Hz 1600
• Voltages from 380 V to 11 500 V
1200
• Shaft heights: 355 - 560 mm kW
800
14.5 - 22.0 inches
• Horizontal or vertical 400

• IP55 / IP56, IC411 / IC416 0

2 4 6 8 10 12 poles
• TEFC / TEAO 3000 1500 1000 750 600 500 rpm
• Standards IEC, NEMA, CSA...
• Motors for marine applications (LRS, DNV, BV, GL, ABS...)
• Motors for classified areas HXR Output at 4000 V 50 Hz
• Motors for VSD
3000
2500
Wide range of other features available on request.
2000
kW 1500
1000
500
0
2 4 6 8 10 12 poles
3600 1800 1200 900 720 600 rpm

ABB 3
 High efficiency means
low running costs

These motors are extremely efficient, even at partial load,

and they have very low noise level. Losses are minimized
by effective use of material and optimized fan designs.
Because of reduced fan and core losses, there is no sharp
drop in the efficiency curve at partial load.

The permissible starting time and, correspondingly, the

permissible load inertia are being constantly increased by
strengthening the mechanical structure of the motor and by
optimizing the electrical dimensioning.

In spite of the minimized losses of present construction,

ABB engineers are constantly working to improve
efficiency. Meanwhile, they are also concentrating on
making the HXR series among the most silent high
efficiency TEFC motors available - less than 80 dB(A) at one
meter on most ratings.

One of the most valuable targets of ABB engineering is to

develop environmentally sound technologies and products.
HXR motors represent these goals with long lifetime, high
efficiency and low noise level.

Value for money at low noise

Typical values of high voltage 4-pole motors.

Output Efficiency %
kW 4/4 load 3/4 load 1/2 load
500 96.7 96.7 96.1
630 97.0 97.0 96.4
710 97.1 97.1 96.5
800 97.3 97.2 96.8
900 97.4 97.4 96.9
1000 97.4 97.4 97.1
1250 97.6 97.7 97.5
1400 97.8 97.8 97.5
2000 97.9 97.8 97.5

4 ABB
Constructed to run cool

One important component of a rib cooled R & D:

motor is the rigid cast iron frame. That
Our research and development program
is because frame design is closely tied to
ensures that our motors utilize the latest
factors such as mechanical stability, ability to
technology and materials to provide improved
withstand harsh environment, and cooling
performance and reliability. We endeavour
efficiency.
to introduce each improvement resulting
The motors are totally enclosed (IP55 to IEC) from innovation, new materials or new
and provided with external fan and cooling manufacturing methods quickly so that the
ribs (IC411 to IEC). benefit is passed to our customers as soon as
possible. The close proximity of our research,
The cooling area of the ribs is large and the design and manufacturing facilities enable us to
form of the cooling ribs is optimized. The form do this very effectively.
of the ribs also keeps the air flow close to the
motor surface along its entire length which
means, besides efficient cooling, a good self
cleaning capability. The air gaps between the
rib ends and the fan cover also facilitate the
self cleaning capability.

Inner surface of the frame and the outer stator

core surface are accurately machined to
accommodate a shrink fit. This minimizes
the thermal resistance between the
stator core and the frame and thus
improves cooling.

Unidirectional fans are standard on

two and four pole design in order to
reduce the noise level and windage
losses. Bidirectional fans are used
on lower speed motors. The fans are
normally made of welded steel plate.

Solid, long life stators

The stator winding design of the motor combines
the class F insulation system with vacuum pressure
impregnation (VPI). This method has been used since
1977 and it is well known for its high reliability.

While the insulation meets the requirements of thermal

class F (temperature limit 155 ºC), the motors are
normally rated to class B, which gives a good overload
margin and provides long lifetime. Basic impulse level
exceeds IEC requirements. The windings are designed to
cope with the highest mechanical stresses including the
effects of rapid autoreclosure in phase opposition.
ABB 5
 Rigid rotor construction

For optimum performance and maximum rotor life, most rotors are built
using copper bars and end rings.

The rotor cage of motors is made with deep bars. The

squirrel cage is either copper, copper alloy or very
conductive aluminum alloy. The copper bars
are silver brazed to copper short circuit end
rings, whereas aluminum bars are made
of extruded rod and are continuous
welded to cast end rings with an
automatic machine. In both cases great
care is taken to minimize stress build-
up. The use of swaged rotor bars
provides a very robust construction
able to withstand heavy duties.
Each rotor is dynamically
balanced.

Copper bar rotors provide long life with

optimum performance.
Accurate computerized dynamic
balancing is made for every rotor.

Low vibration
The patented rotor construction
guarantees outstandingly low
vibration level. Even for 2-pole
motors the typical vibration values
are less than 0.8 mm/s at 3000 rpm
or peak-to-peak displacement less
than 0.3 mils at 3600 rpm.

These low vibration levels are

also unaffected by changes in the
motor temperature, i.e. vibration
level remains stable from cold
start to full temperature operation.
Vibration measurements are taken
on fully assembled motors to
verify compliance with applicable
standards.

6 ABB
Reliable bearings

Angular contact ball bearing

(N-end in vertical motors)

D-end N-end
Axially locked Axially free

Deep groove bearings

Antifriction bearings Labyrinth type bearing seals prevent

Horizontally mounted motors of the 355-500
series have deep groove ball bearings in both
ends in the standard bearing solution. The
bearing construction has been tested for degree
of protection IP55, optionally motors can be
offered with IP56 protection. The 560 series
has two bearings (deep groove ball bearing
and cylindrical roller bearing, type NU) in
D-end and cylindrical roller bearing in N-end.
In vertical motors of the 355-500 series the
rotor weight is carried by a single row angular
contact ball bearing in N-end. The 560 series
has two angular contact ball bearings in
tandem arrangement in N-end. The axially
free bearing is spring loaded to allow thermal
expansion and to reduce noise and vibration.
When a greater radial load capacity is required,
for example in a belt drive, an optional
cylindrical roller bearing (NU) can be used at
the D-end of the motor.
The bearings are relubricated with grease while
the motor is running. Excess and waste grease
is removed out of the bearing construction
through a valve and from an opening in the
outer bearing cover.
contamination of the bearings by airborne
particles. Joint surfaces are sealed with sealing
compound to ensure best possible protection
of the bearings.
All motors are provided with SPM-nipples
(Shock Pulse Measuring) as standard on both
ends of the motor. Thus the condition of the
bearings can be checked easily while the
motor is running. Provisions for resistance
temperature detectors (RTD) are standard.
Sleeve bearings
Oil lubricated sleeve bearings are provided
for horizontal motors as an option. Standard
bearing design is a side flange split type
bearing. Normal rotor float range is ±8 mm
from the mechanical center.
The oil level can be checked from a sight
glass from either side of the motor. Oil filling
and drainage are easily carried out. Protection
against contamination is provided by floating
type labyrinth seals.

ABB 7
 Low voltage
Adaptable terminal boxes allow
terminal boxes convenient cable
entry from left or
right hand side.

Connection of the cables is simple to carry out

in the spacious terminal box, which can also
be changed from side to side after installation.
The standard location of the main terminal box
is at the D-end of a horizontal motor and at the
N-end of a vertical motor. The terminal box is
supported by rigid fixing beams on the motor High voltage terminal
boxes can be rotated,
frame.
even after initial cable
The boxes are made of fabricated steel connection. They are
equipped with pressure
welded constructions. A variety of different
relief valve.
HV terminal boxes, e.g. star point box, phase
segregated box or phase separated box are
available. There are also several options for
cable sealing.

Optional accessories,
such as current
transformers and
surge capacitors,
are available to
adapt the HXR
motor completely
to the operating
environment.

In low voltage terminations up to 8 conductors

per chase can be used.

All auxiliaries are

wired to a separate
connection box. The
connection diagram
is attached inside the
cover.
In low voltage
terminations up to 8
conductors per phase
can be used.

8 ABB
Comprehensive range of
accessories

The following accessories are included

as standard:
• 6 Pt 100 resistance temperature detectors (RTD)
in the stator winding, wired to a separate terminal box
• SPM- and grease nipples on both antifriction bearings
• labyrinth seals on bearings
• grounding bolts on frame and inside and outside
of the terminal boxes
• stainless steel rating plate
• jacking screws
• lifting lugs
• provision for dowel pins

Comprehensive range of designs and accessories

The design of HXR motor makes it possible for the customer
to choose from a wide range of proven accessories and to
customize his motor to conform with his requirements.
Please contact ABB for further information
of other optional accessories

Thorough testing

The careful design and manufacture

of the motors assure the consistent
production of the finest quality
machines. ABB uses cost effective
production processes meeting
the strictest quality requirements.
Extensive testing during
manufacturing and final assembly
verifies the high quality of the
motors.

After a motor has been type tested

for electrical characteristics, all
subsequent motors of the same type
undergo an extensive routine test
program.

Each motor is routine tested. The test facilities are also capable of carrying out more
extensive tests.

ABB 9
 Motors to fit your process

Wide range of applications

ABB has unique experience in providing power
equipment, automation and control systems for
industry’s many complex processes. In this sector,
there is no substitute for experience. To be an
Dedert Corporation, the Netherlands, MVR Fan applications,
innovative, reliable partner, we have to know your
evaporator fan
business as well as our own.

Totally enclosed fan cooled (TEFC) motors are
suitable for almost every environmental condition.
Typical applications include pumps, fans, blowers,
compressors, conveyors, pulverizers, ship thrusters
and AC generators. ABB is also a leading supplier
of AC motors, generators and drives for the
chemical, oil and gas industries. These motors
have been developed for hazardous conditions
against exceptional forces of nature and danger of
explosion.
A high voltage HXR motor is well suited to drive
energy efficiency blowers or fans thanks to its
good starting characteristics. A motor has high
efficiency both at full and partial load which
brings major benefits in continuous operation.
Pump drives in power plants and process
industries are one of the many applications.
Together with ABB’s skilled personnel you can
select an optimal motor for your application.
We are committed to giving you added value
by providing technically outstanding solutions
optimized for your needs.

Medium voltage
AC drives

Variable speed drives

Suitable for frequency converter control Sectional
There are as many potential variable speed drives
applications in industry as can be imagined. A The motors
major advantage of an AC drive is the use of a are optimized
cage induction motor which is the most versatile, for different
reliable and economical prime mover. drives
by applying customized
The speed of HXR motors can be smoothly
dimensioning. Electrical dimensioning is
controlled down to zero when specified to be
carried out in order to ensure the best possible
used with frequency converters. In constant
performance of the drive and to fully utilize
torque applications, non-fluctuating torque can
the frequency converter. In many cases power
be achieved. Short torque response times and
demand can be satisfied with a smaller inverter
high dynamic speed control accuracy are standard
unit.
features.
In large projects the amount of motor types can
The form-wound winding construction is in
be reduced in order to reduce the requirement
motors as standard. This construction yields very
for spare motors to a minimum. Our ability to
moderate voltage stresses between the winding
offer a flexible solution to meet the customers’
elements even when supplied with the most
requirements is appreciated by our customers all
efficient inverter types and the steepest voltage
around the world. During the last decade we have
pulses. Therefore no chokes or filters are needed
delivered, in addition to smaller units, hundreds
which results in simpler installation, lower losses
of motors over 500 kW for sectional drives and
and better performance for the entire drive
winders.
system.
10 ABB
Many good reasons
to choose HXR motors

• over 100 years experience

• high efficiency
• low noise
• low vibration level ABB’s AC 12 pulse frequency converters drive the river
water intake pumps at Tale and Lyle Sugar’s Thames
• long lifetime refinery.
• VPI insulation system
• modern design
• comprehensive accessories
• short delivery time
• many international standards
• global ABB service network
• ISO 9001 quality certificate
• ISO 14001 environmental certificate

Dagang paper mill.

Worldwide service network

Motors are designed and manufactured to operate
without troubles, year after year, with a minimum
of maintenance. In the event that service is needed,
ABB’s worldwide network is always available to
support you with local representative. Our multi-
domestic presence saves valuable time and costs
by ensuring the continuous operation of our
customers’ processes.
The information and specifications contained in this brochure
are subject to change without notice.

Meri-Pori Power Plant, coal pulverizer motor

ABB 11
 Printed in Finland, 05-2005/5 000/Oy Litoset Ab
ABB (www.abb.com) is a leader in power and automation technologies that enable utility and
industry customers to improve performance while lowering environmental impact. The ABB
Group of companies operates in around 100 countries and employs about 100,000 people.

ABB’s web site provides further information.

Please go to http://www.abb.com/motors&drives.

Piirtek#11832
Brochure BU/HXR motors GB 04-2005

http://www.abb.com/motors&drives ABB reserves the right to change the design, technical specification and dimensions without prior notice.