ABB’s Integral Motor

– the ultimate pump drive

ABB Motors
New possibilities for pump
manufacturers and users

The solution lies in allowing a motor with variable

speed to drive the pump, whereby the power is
continuously controlled by the speed instead of
traditional inefficient throttling. This is why we
have developed a product that opens up new possi-
bilities both for pump manufacturers and users
- ABB’s Integral Motor.

Optimum process efficiency and

major energy savings
In all pump installations the aim is to achieve high
efficiency and reliability combined with low energy
consumption and minimum environmental impact
(especially regarding noise level).
In recent years, in industry and the housing
sector, the focus has increased on improving the
utilisation of electrical energy. Gone are the days
when saving energy meant developing more efficient
motors and pumps as such. Instead we are talking
about optimising the entire process and the possi-
bility of reducing the total consumption of energy.
The only way of meeting these demands is to
take into account process requirements in operating
the pump. This presupposes a motor with speed
and power adapted to the required load – a speed-
controlled motor such as ABB’s Integral Motor.

Transportation of liquids is one of the most
common applications of motor drives. There are
millions of pumps all over the world: in process
industries and power plants, in municipal potable
water, district heating and sewage plants, and in
offices/housing for distribution of potable water
and heating.
Almost all of these pumps are driven by
standard motors with constant speed.
The motors run at full speed and the pump out-
flow is regulated by a throttling valve. In this area
there is an enormous potential for saving
energy and costs!
Improved reliability, longer life and
lower maintenance costs
Capacity control by means of throttling valves in a
pump operating at maximum speed often increases
the shaft pressure by up to ten times. This means
that the bearings of both pump and motor are
subjected to hard wear.
By letting the motor speed control the pump
capacity entirely according to the process require-
ments less wear on bearings and sealings is achieved.
The soft start and lower average speed of the integral
motor also provides advantages such as reduced
cavity and vibration damage, and less unplanned
process downtime.

Power
100%

3000 r/min 0-6000 r/min

Starter Gear
Energy
Pump savings Pump
50%

Throttling

Regulator

Power required
Flow by pump Flow

Pump driven by a constant-speed motor with 50% 100% Pump with speed-controlled integral
Flow
throttle control motor
2
 Before After

Variable speed results in more

competitive pumps
Valve
ABB’s Integral Motors allow an extended speed
range, which opens up new possibilities of opti-
mising pump equipment. Speeds up to 6,000
r/min eliminate the need for mechanical step-up
gears for high-pressure pumps. Higher speeds
require fewer wheels in the pump, and indirectly
a smaller pump house, in order to achieve the
same pump capacity.
In low-speed pump applications ABB’s Integral
Motor can be used instead of 4–8-pole motors of
The pump is driven by a motor The pump is driven by an ABB
the same physical size. Smaller pump size,
that is running at maximum Integral Motor with variable reduced manufacturing and maintenance costs
speed - the outflow is controlled speed - the outflow is controlled
by a throttling valve. by the motor speed. - these are important advantages for pump
users and manufacturers.
Fast and easy installation
It is very easy for users in the process industry,
for example, to upgrade existing pumps driven by
a constant-speed motor:
1. Replace the motor with an ABB Integral Motor
2. Open the throttling valve completely
3. Connect the output signal from a flowmeter or Less environmental impact
pressure gauge to the Integral Motor’s input. Thanks Replacing a constant-speed, throttle-controlled
to the built-in PID regulator, an energy-saving motor with an ABB Integral Motor can mean a
pump operation is achieved. reduction of energy consumption by up to 50%.
In a process industry, this can mean a reduction
A wide speed range means smaller in energy needs of about 10%. In addition, the
inventories average noise level for the pump installation is
Traditionally, pump suppliers have worked with halved - a major step towards a better working
hundreds of pump/motor combinations, which has environment.
imposed requirements of comprehensive and costly
motor inventories.
Power
Using ABB’s Integral Motor means that the
number of pump variants can be minimised. A few
pumps of different sizes driven by ABB’s Integral
Motors can replace a large number of constant-
speed-driven standard pumps (see figure below).
In addition, there is no need for throttling valves.

Head
0 1000 2000 3000 4000 5000 6000
(r/min)

Pump 1
Meets the EMC guidelines – copes
with hostile industrial environments
Pump 2
ABB’s Integral Motor is CE-marked and meets the
Pump 3 requirements of Machine, Low-Voltage and EMC
directives. This is a comforting thought at the
design stage of a new pump installation – in addi-
tion, the pump manufacturer does not have to
Flow reclassify the equipment.

3
ABB’s Integral Motor – the real answer
to demanding special applications

Magnetically driven, leakage-free

pumps
Pumps with magnetic coupling are often used
for transportation of aggressive liquids. The shaft
seal is then replaced by a maintenance-free metal
encapsulation in a magnetic enclosure/connec-
tion, which provides a 100% leakage-proof
design. The disadvantage is the power loss in
the sealing encapsulation. This is propor-
tional to the square of the speed.
An ideal solution for magnetically
driven pumps is to control the capacity
using the speed of the Integral Motor instead
of running a standard motor at full speed
combined with a throttling valve. Thus, much
of the power loss in the sealing encapsulation
can be avoided, at the same time as efficient
and safe pumping is achieved.

Circulation pumps in buildings

Most circulation pumps in heating systems
are run at full speed irrespective of the actual
need of hot water flow. This is a waste of energy
involving high costs and, in addition, generating
disturbing noise in water pipes and valves. ABB’s
Integral Motor, combined with a circulation
pump, provides a simple energy-saving installa-
tion, with integral functions controlling the
pump at variable speeds – all according to the
capacity required.
Due to the reduced average speed, wear on
bearings and sealings is also reduced, and thus
maintenance and downtime. Reduced speeds
combined with soft starts also means lower
noise levels in the building, except for the few
occasions when the pump is working at full
capacity.

4
 Installations prove
Integral Motor benefits
Water injecting pump in cement plant at Blue Circle
Cement, Ashbourne, Great Britain
Task: To inject water into
the cement mill through
a spray nozzle.
Earlier solution: Fixed
speed motor driving the
pump, and a control
valve regulating the
water flow.
Experience: The control
valve was unreliable,
expensive and inefficient
according to Tony Carr,
Electrical engineer at

ABB’s Integral Blue Circle.

Present solution:
The ABB Integral Motor

Motor is drives the pump. The

water flow is continuously controlled by varying the speed of the Integral Motor
utilising the analogue input.

the solution Experience: The Integral Motor is less expensive than the control valve, claims
Tony Carr. In addition, it is available at the same cost as a separate frequency
converter, a separate motor, screened cable, EMC-filter and commissioning.

for you It is well suited for the dusty environment as the converter part is fitted at the
non-drive motor end and cooled indirectly by the motor fan. Though the energy
saving with the 1.5 kW Integral Motor may seem insignificant in a 16 MW
operation, efficiency is something we look at in all our motor installations,
ABB’s Integral Motor consists of a standard-type says Carr.
AC motor with a built-on frequency inverter and
an EMC filter. The motor and inverter have Feeding pump from APV Fluid Handling/Danmark in
been optimised to each other and are perfectly pasteurising plant
matched. Most parameters have been pre-set at Task: To feed milk
the factory, which guarantees efficient and safe products from a tank to
operation. the pasteurising equip-
ABB’s Integral Motor is designed for opera- ment at different flow
tion in dusty, damp and corrosive environments rates depending on the
type of product.
(protection class IP55). Five motor sizes cover
Earlier solution: Fixed
the power range 0.75 - 7.5 kW. They are con-
speed motor driving the
nected to 380 – 460 V, three-phase (the smallest pump. A throttling valve
motor requires 200 – 240 V, single-phase) and adjusted the flow.
can operate at temperatures between -25° C Experience: The thrott-
and +40° C. ling valve was set accord-
ABB’s Integral Motor is available in a low- ing to the product
speed version (300 – 3,000 r/min) and in a requirements for one of
high-speed version (600 – 6,000 r/min). It is the milk products. Thus,
the flow was incorrect for
CE-marked and meets all current EMC require-
all other milk products.
ments.
Present solution: A 4 kW ABB Integral Motor drives the pump. The fluid
ABB’s Integral Motor has been developed flow is continuously controlled by varying the speed of the Integral Motor
so as to cope with most pump applications, for utilising the built-in PID-regulator.
example pumping water, sewage, pulp, solvents Experience: The W+FreCon type pump from APV comprising the Integral
and salt solutions. If connected to process, Motor fits APV´s customer’s demands in a perfect way. It is highly suitable for
dosage or centrifugal pumps, it can control flow, maintaining constant product temperature, flow or pressure. The installation
pressure, level and volume continuously. time and thus cost are reduced. There is no cabinet installation for the fre-
quency converter, no wiring between motor and converter and no fitting
ABB’s Integral Motor – the perfect drive package of separate EMC-filters. APV markets their W+FreCon pumps with
for pumps. ABB Integral Motors in the power range 0.75-7.5 kW.

5
ABB Motors
Manufacturing sites* and some of the biggest sales companies

THP Producentreklam. Printed in Finland 1998

ABB Motors
Marketing Communications
P.O.Box 633
FIN-65101 Vaasa Finland
tel. +358 10 22 4000
fax +358 10 224 7372 Pump application BA/Integral motors GB 98-10
www.abb.com/motors