Product portfolioBU LV Motors

Process Performance General PerformanceM3BP 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

AluminiumCast 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 60034-31IE 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 PLL 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

POutput

rpm

load

PInput

LossesP

P OutputInputP

POutput PLossesPOutput +

PInput

PInput PLosses

Energy supply

Pinput = Electrical power inputPoutput = Mechanical power

output

Pfriction & windage

Poutput

PLL

Pwinding

Pinput PironProtor

Stator winding losses (Pws) Rotor losses (Pwr) Iron losses (Pfe)

Additional load losses (PLL)

Additional load losses are due to: Friction + Windage losses (Pfw) 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(Pin)

Mechanical energy out (Pout)

Pcu1 35 %Stator winding

Pcu2 20 %Rotor winding

PFe 20%Iron

PFr Friction 10 %

PLL 15 %Additional

Pout 94 %

Mechanical energy out

Losses 6 %

PoutPin

= 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

0 1 MW

75 355 kW

0.12 1000 kW

0.12 630 kW

11 355 kW

Process performance motorsIE2 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 MWType M3BP / M3AAFrame 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 motorsIE2 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 kWType M2BA / M2BAT /

M2AA / M2CAFrame sizes 71 to 355 in cast iron

56 to 250 in aluminum280 to 400 in steel

*) availability to be checked for sizes up to 132

Key to success

Losses

Elimination of rotor losses

I2RStator

I2RRotor

Other

I2RStator

Other

I2RStator

Other

IE2 induction motor

IE4 SynRM motor

High Output SynRM motor

100%

60%

80 -90%

Two new innovative motor-drive packagesThe technology for variable speed applications

Standard motor

+special rotor

Standard drive+

new software

SynRMmotor-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 packageWhat 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 IE2induction 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 motorsEx 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

0 1 MW

0.55 750 kW

Worker Protection Directive 1999/92/ECZones

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 conditionPresence of explosive atmosphere only by accident, but not during normal duty ( 10 h per year)

Zone 1(G) / 21 (D) OccasionallyIncidental presence of explosive atmosphere during normal duty (10 to 1000 h per year)

Zone 0 (G) / 20 (D)ContinuouslyPermanent 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 conditionPresence of explosive atmosphere only by accident, but not during normal duty ( 10 h per year)

Zone 1(G) / 21 (D) OccasionallyIncidental presence of explosive atmosphere during normal duty (10 to 1000 h per year)

Zone 0 (G) / 20 (D)ContinuouslyPermanent presence of explosive atmosphere (> 1000 h per year)

Category 1

Category 1 or 2

Category 1, 2 or 3

Risks associated with explosive atmospheresEffects 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 atmospheresSparks 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 atmospheresProtection 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 atmospheresProtection 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 atmospheresProtection 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 T6450 C 300 C 200 C 135 C 100 C 85 C

Risks associated with explosive atmospheresProtection 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 ConformityABB 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 standardmotor 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 dEx 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 sizePN < 100 kW PN 100 kW or PN 350 kW or IEC 315 IEC 400

UN 500 V Standard motor Standard motor Standard motor+ Insulated N-bearing + Insulated N-bearing

+ Common mode filterUN 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 filterReinforced insulation Reinforced insulation OR

+ Insulated N-bearing Reinforced insulation+ Insulated N-bearing+ Common mode filter

UN 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 motorsProduct presentation

High voltage cast iron motors Wide product range

Product strategy: HXR engineered motorM3BM standard catalogue productU / 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 450NEMA 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, HXRWide 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 +60CAmbient -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 offeringFlameproof 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 offeringSlip-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 offeringSynchronous 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 pictureMoving the focus to decades of use

Energy 97%

Onerewind 1%

Initialpurchase 2%

BU LV MotorsEnergy facts about LV motors

Loss6.4 kWLosses at 92.1 %

Loss3.8 kWLosses at 95.1 %Reduced losses = 2.6 kW

Savings 1251 EUR per year = 11 tonnes CO2 (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 MotorsABB 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