emz high-voltage motors & large drives

EMZ High-Voltage Motors & Large Drives Special Cement Edition

→ EMZ Products → Spare Motors & Replicas → Repair & Service → Engineering

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EMZ Cement special

Preface

Dipl.-Ing. Benedikt Mathiaszyk

Managing Director Large Drive & Projects

Dear Ladies and Gentlemen,We are pleased to present our product series of high-

voltage motors and large drives to you with this spe-

cial catalogue which is exclusively compiled for the

cement industry.

Thanks to our years of experience with custom-

ers from the cement industry, we are familiar with

the comprehensive requirements of internationally-

operative OEMs and know the practical needs of the

operators in the plants.

EMZ stand for products and services of excellent

quality, quick delivery, and competitive prices. With

the use of modern manufacturing processes and high

quality materials, we guarantee maximum reliability

and operational safety for our high-voltage motors and

large drives.

Our qualified sales team take your individual require-

ments into account and provide personal, expert

advice to help you choose the right high-voltage drives

and complete drive-systems.

Ask us; we will be delighted to assist you with your

enquiries and look forward to working with you.

EMZ‘s premises in Recklinghausen

cover 20,000 m2, whereby 5,000 m2

alone are for warehousing, a further

1,800 m2 for workshops and 800 m2

used for office space.

01 Production 03 Repair & Service

02 Spare Motors & Replicas 04 Engineering

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EMZ supplies high-voltage motors and large drives for

all kinds of applications in the cement industry. The

motors are manufactured in accordance with IEC and

EN 60034 standards. They comply with all interna-

tionally applicable regulations.

On request, the EMZ motors can be manufactured

according to NEMA MG2 standards and IEEE testing

regulations.

The high quality standards of the

EMZ products are guaranteed by

the certification of our quality as-

surance system in accordance

with EN ISO 9001 standards.

Available from stockWe stock up squirrel-cage motors up to 6,000 kW, as

well as slipring motors up to 5,000 kW. Therefore, our

well sorted warehouse enables prompt delivery in

case of emergency or damage.

Applications for EMZ motors → Ball mills

→ Vertical roller mills

→ Roller presses

→ Crusher

→ Kiln drives

→ Fans

→ Conveyor belt

Applications

Ball mill Vertical roller mill

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EMZ Cement special

AKR & ASR motors are surface cooled according to

IC411 (IEC 60034-6). A compact design and great reli-

ability characterise our motors.

AKR series Squirrel-cage motorsASR series Slipring motors

The motors are available in the IEC frame sizes 315,

355, 400, 450, 500, and 560mm and can be manufac-

tured with a maximum output of 2,000 kW.

EMZ AKR & ASR motors are suitable for heavy and

extreme conditions. They are available in standard

design for operation with fixed speed but also for speed-

regulated use with frequency converters.

01 ProductionAKR & ASR Motors

Squirrel-cage motors AKR 355-04 for conveyor drive Slipring motor ASR 450-06 for coal mill drive

Design→ Compact cast-iron housing

→ Two-circuit cooling system for internal and

external cooling

→ Reliable bearing design with SKF/FAG

rolling bearings

→ VPI insulation system in thermal class F

→ Use of copper rotors for difficult start-up

conditions for AKR motors

→ Designed for operation with fixed speed

and for VFD application

Power range→ Performance 150 to 2,000 kW

→ Voltage 2,000 to 13,800 V

→ Frequency 50 and 60 Hz

→ Number of poles 2 to 12 pole

→ Protection type IP 55

→ Cooling type IC 411

→ Mounting IM B3 and IM V1

Surface cooled three-phase motors AKR & ASR series

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AK Motors

AKL 710-06, 2,500 kW, 6,000 V, 990 rpm for fan application AKL 560-06,1,200 kW, VFD for heat exchanger fan

Based on the basic module of a welded stator hous-

ing, the squirrel-cage motors of the AK series can be

adapted perfectly to suit the individual requirements

of each application. They are available for use with

fixed speed and for VFD applications.

Designs(type designation according to IEC 60034-5/6):

AKD series

Protection type IP23/W24/R54 | Cooling type IC01/31

AKL series

Protection type IP55 | Cooling type IC611/616

AKW series

Protection type IP55 | Cooling type IC81W

The rotor cage construction of the basic design is made

of rectangle copper bars which are hard-soldered with

the grooved short circuit rings. For special applications

with difficult start-up and operating conditions, we can

use double-cage rotors.


→ Voltage 2,000 to 13,800 V



→ Protection type IP 23/W24/R54/55

→ Cooling type IC 01/31/611/81W

→ Mounting IM B3 und IM V1/V10

Modular three-phase squirrel-cage motors AK series

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EMZ Cement special

EMZ slipring motors are used in the cement produc-

tion when a high starting torque and/or a low starting

current is/are required. Identical to the modular cage-

rotor series, the slipring motors of the AS series are

developed onto the basic module of the welded stator-

housing construction.

The following designs are available(descriptions according to IEC 60034-5/6):

ASD series

Protection type IP23/W24/R54 | Cooling type IC01/31

ASL series

Protection type IP55 | Cooling type IC611/616

ASW series

Protection type IP55 | Cooling type IC81W

Massive shaft design for second shaft end By using massive shafts, all slipring rotors can be con-

structed with a second shaft end designed for twice

the nominal torque. The rotor winding is executed in

thermal class F and manufactured as a corded two-

layer winding. Further, the individual rotor bars are

hard-soldered after insertion and secured with a stur-

dy bandage against the occurring centrifugal forces.

BearingsWe can guarantee a long service life and low main-

tenance costs by using high-quality rolling bearings

manufactured by SKF and FAG, and sleeve bearings

which are manufactured by Renk.

Raw mill fan

ASL 560-06 1,400 kW

Ball mill drive

ASL 630-06 4,200 kW

Modular three-phase slipring motors AS series

01 ProductionAS Motors

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Sliprings and carbon brushesThe standard version slipring motors are available with

permanently-mounted carbon brushes or, on request,

with a short-circuit and brush-lifting device. Essential

criteria for low wear-and-tear parameters are the use

of high-quality carbon brushes and brush holders, as

well as the load-optimised design of the carbon brush-

es. Taking all of this into account, our ASL slipring mo-

tors ensure a maximum operating availability.


→ Voltage 2,000 to 13,800 V



→ Protection type IP 23/W24/R54/55

→ Cooling type IC 01/31/611/81W

→ Mounting IM B3 and IM V1/V10

Ball mill drives

4,800 kW and 4,200 kW

Slipring motor ASL 630-06

3,500 kW, 11,000 V, 992 rpm

AccessoriesAll EMZ high-voltage motors can be equipped with a

wide range of accessories:

→ Pt100 resistance thermometers for winding

and bearing

→ SPM detectors and vibration monitoring 4-20mA

→ Bentley Nevada vibration monitoring

→ Anti-condensation heating elements

→ Contact thermometer

→ Star point terminal box

→ Current transformers for differential protection

→ Tachometer generators

→ Slipring room lighting

→ Pressure switch for filter monitoring

Modular three-phase slipring motors AS series

AS Motors

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EMZ Cement special

Liquid starter DFA 2000 for ball mill

ASD 710-12, 2,000 kW, 10,000 V, 495 rpm

1,500 kW; 6,000 V Soft starter.

Oil-cooled drum startersThe oil-cooled drum starter consists of individual cast

iron elements which are manufactured according to

the required resistance parameters and mounted in an

oil reservoir.

Liquid startersThe liquid starter is a con-

tinuously-adjustable resistor

with a three-phase electrode

system which is moved in an

electrolyte. Through the con-

centration of the electrolyte,

the starter resistance can be changed and the starter

optimally adjusted to the respective load conditions.

Medium-voltage soft startersOur electronic soft starters allow a controlled reduc-

tion of the starting current and the start-up torque

when starting squirrel-cage motors.

Power range→ Performance max. 16,000 kW

→ Nominal voltage 1,500 to 15,000 V

Technical Data→ Vacuum contactor

→ Vacuum bypass contactor

→ Motor-protection relay (MSR)

→ Multifunction display (DMA)

→ Current limiting

→ Adjustable torque and current characteristics

→ Boost start (high starting torque)

01 ProductionStarters

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ApplicationsVariable speed drives with asynchronous motors and

frequency converters are used in many different ap-

plications with various operating conditions. You can

find a lot of these drives operating fans and kilns in ce-

ment factories. Increasingly, these frequency convert-

ers are also used for high performance vertical roller

mills. A process-conditioned adjustment of the grind-

ing table rotation speed can increase the production

capacity and optimise the grist quality.

Optimised drive solutions We offer practicable drive solutions that are custom-

ised to fit your requirements and processes. On the

basis of our experience and expertise we are able to

compile selected components for the ideal drive solu-

tion that will meet all your expectations.

Frequency converter during the final inspection Frequency converter 1.2 MW

Medium-voltage frequency convertersMedium-voltage frequency converters are used in ap-

plications where powerful speed control is required

and where low-voltage frequency converters have

reached their economic and technological limits. With

these, the rotation speed and the torque of asynchro-

nous and synchronous machines are optimally adapt-

ed to suit the actual requirements; energy consump-

tion is optimised and the CO² emissions reduced.

Technical designs Direct converters which can be put “direct to drive”

without a matching transformer are available for volt-

ages up to 6,600 V and a max. current of 285 A. The

quality of the output voltage as almost perfectly sinu-

soidal enables the use of existing motors without re-

ducing the nominal output for constant speed opera-

tion with 50 Hz.

Frequency Converters

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EMZ Cement special

New replaceable spare motors without any reconstructionMany main drives in cement factories have been in use

for decades in severe application conditions, operating

as drives for cement mills, crushers, and fans. These

drives are often designs with base frames in the frame

size D5/IM7211. The stator housing and the pedestal

bearing housings are mounted on a separate steel

base frame. With these designs, the use of modern re-

placeable spare motors with the frame size B3/IM1001

is often dependent on expensive and time-consuming

modifications executed on the foundations.

With our know-how, EMZ can offer you replaceable

spare motors specialised for these drives. Our motors

can be fitted on-site on the existing base frame. We

take into account that the base frame will be loaded

at the identical positions compared with the origi-

nal motor. Further, we consider the matching for the

stator- and rotor connection.

EMZ offers the perfect solution→ Accurate recording of the actual state of

the application in your facility

→ Comparison with current requirements

→ Development of a suitable concept together

with the operator

→ Detailed co-ordination of construction and

accessories

→ Routine and type testing according to

IEC/EN 60034-1

→ Installation, commissioning, and training

Ball mill 1,700 kW, 10,000 V, 495 rpm Ball mill 2,400 kW, 10,000 V, 495 rpm

02 Spare Motors & Replicas Spare Motors

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Based on our experience and the numerous success-

fully-completed projects, we guarantee an all-around

service when you require replaceable spare motors.

Our specialists come to your plant and gather all rele-

vant data that we need in order to prepare a quotation

for a 100 % interchangeable spare motor.

Advantages for the operator→ 1:1 mechanical interchangeable

→ Structural modifications of the foundation are

not necessary

→ Identical position of the stator- and rotor

connection

→ Identical cable entries for stator and rotor cables

→ Identical electric data for stator and rotor winding

→ Application of the existing rotor starter

→ Application of the existing coupling half on

the motor side

→ Production safety due to the modern VPI insulation

system thermal class F, utilisation according to

thermal class B (85K)

→ Improvement of efficiency due to the use of

loss-optimised electrical sheet steels

→ The brushes equipping is optimised according

to the plant conditions

→ Short reconstruction period due to guaranteed

interchangeability

Ball mill 3,600 kW, 3,300 V, 595 rpm Vertical roller mill 5,500 kW, 3,300 V, 990 rpm

100% interchangeable replicas for existing motors

Replicas

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EMZ Cement special

Case study 1 Case study 2Our customer in Germany required a spare motor

which will be used as an interchangeable spare motor

for 3 identical cement mill drives. The supplied motor

with the design B20/IM1101 can be mounted and con-

nected without any further modifications on the exist-

ing base frame on-site.

In this case, the installation conditions of the 3,500 kW

motor were extremely confined. The spare motor

ASL 630-06 had to be 100% mechanical and electri-

cal interchangeable. This means that the dimensions

and position of the insulators in the stator and rotor

terminal box needed to be identical. As desired by the

customer, an additional set of Rogowski coils for the

differential protection monitoring was mounted.

Ball mill – original motor

1,700 kW, 10,000 V, 990 rpm

Type test – spare motor

EMZ ASD 630-06, 1,700 kW, 10,000 V, 990 rpm

Slipring motor EMZ ASL630-6 during installation

3,500 kW, 11,000 V, 992 rpm

Ball mill drive brand Converteam in UK

3,500 kW, 11,000 V, 992 rpm

02 Spare Motors & Replicas Case Studies

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Ball mill drive in UK, year of construction 1967

1,700 kW, 11,000 V, 500 rpm

Coal mill drive in Malaysia

Siemens type 1LS1 454-6, 350 kW

Case study 3 Case study 4Our customer from England operates very special syn-

chronous slipring motors in 2 production facilities. We

manufactured a customised spare motor. This asyn-

chronous slipring motor has the special design D9/

IM7201 and can be mounted on the existing base frame.

Since the base frames of the original motors in both

production facilities are not identical, the spare motor

can be adapted to fit the respective installation condi-

tions by using adapter plates.

Our customer is using a slipring motor from Siemens,

type 1LS1 454-6, which is no longer available now-

adays. We supplied a 100 % interchangeable spare

motor that is a customised construction from EMZ

which was manufactured with a second shaft end for

the auxiliary drive. For the operator it was possible to

install the motor without making any further adjust-

ments.

Replacement s pare m otor d uring a cceptance t est

1,700 kW, 11,000 V, 494 rpm

Spare motor EMZ AKS 450-06

350 kW, 6,000 V, 990 rpm

Case Studies

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EMZ Cement special

Repair & rewindingMany high-voltage motors in cement factories have

been in use for decades in severe application condi-

tions. Older motors especially are often designed with

protection type IP23 or IPR44, as open-through-ven-

tilated motors where the stator and rotor winding is

cooled directly by inducing the surrounding dust ex-

posed air.

The contamination of the windings in combination with

high humidity increases the partial discharge, which

accelerates the ageing process of the winding insula-

tion. By executing a complete renewal of the stator

and rotor windings to thermal class F, the active parts

will be put into new condition, which guarantees the

operator a high level of reliability.

Our services→ Evaluation of the actual condition of installed

motors on the basis of

→ Machine vibrations

→ Measuring of insulation resistance

→ Bearing analysis

→ Thermography measuring

→ Complete mechanical overhauling

→ Stator and rotor winding renewal to thermal class F

→ Disassembly, installation, laser-supported

alignment, and commissioning

→ Recording of the starting conditions of slipring

motors with a 4-channel recorder

→ Commissioning and set-up of rotor starters

regarding the operating conditions

Disassembly of 1,700 kW ball mill drive Installation of 1,700 kW SR Motor after

stator & rotor rewinding

03 Repair & ServiceRepairs

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Advantages for the operatorCompletely overhauled and on demand winding rene-

wed motors offer many advantages for the operator:

→ High level of reliability and an optimal availability

→ Stator & rotor winding renewal in thermal class F

→ Better insulation strength due to the use of

modern insulation material

→ Thermal reserve capacity due to the increase

from thermal class B to thermal class F

→ Checking, repair, or replacement of

existing bearings

→ Optional retrofit of modern monitoring systems

→ Optimised use of the carbon brush equipping

with regards to the operating environments

→ Reduction of carbon brush wear-and-tear

Mechanical repairs and reconstructionsWe offer you the possibility to modify and reconstruct

your machines.

→ Change of protection type

→ Installation of vibration sensors

→ Installation of tacho-generators and rotation

direction sensors

→ Installation of voltage surge arrestors and

counters

→ Installation of thermal sensors for any

measuring points

→ Change of cooling type due to reconstruction

of the heat exchanger

→ Change of direction of rotation

Rotor rewinding slipring motor 1,700 kW

with new slipring body construction

Stator and rotor rewinding

BBC motor 4,500 kW, 10,000 V, 495 rpm

Rewinding

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EMZ Cement special

The EMZ service concept includes the complete main-

tenance of your motors. We take care of all works,

from installation to commissioning, maintenance, and

repair.

The EMZ service concept→ Delivery & installation

→ Maintenance & inspection

→ Repair

→ Breakdown analysis & repairing of faults

→ Spare parts supply

→ On-site measurements (insulation value,

thermography)

→ Vibration measurements & analysis

→ Starter set-up and optimisation

→ Trainings

EASA MembershipEMZ is an accredited member of EASA since 1997.

Owing to our membership, EMZ is able to rely on 2,000

partners worldwide. Thus, we can provide professional

support worldwide at short notice.

Siemens Solution Partner

As a certified Siemens Solution Partner Automation

Drives for the fields “large drives“ and “motors simolog“

we offer our customers an overall service for the re-

spective Siemens products.

Commissioning ASL 500-04

1,800 kW, 1485 rpm

Installation and commissioning AKD 630-06

5,300 kW, 6,600 V, 1490 rpm

The EMZ service concept

03 Repair & ServiceService Concept

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All measuring and examinations are executed accord-

ing to EN 60034 standards with our own testing sta-

tion. Our qualified staff is available to assist you on-site

for any machine diagnostics.

Range of our EMZ testing department→ Complete no-load testing according to EN 60034

standards up to 6,000 kW

→ Recording of no-load and short-circuit

characteristics

→ Vibration analysis

→ Ascertainment of the polarity index (PI-index)

→ Rotor bar-break testing for three-phase

squirrel-cage motors

→ Hotspot measurement for magnetic core

→ Noise measurement

→ Operational balancing

→ Ascertainment of the magnetic centre and

the axial play

→ Smooth running measurements of

commutators and sliprings

→ Measurements of brush contact pressure

→ Checking of air flow rate and velocity of flow

in the cooling circuit

Complete type testOn request it is possible to execute complete type tests

for all motor types. Depending on the torque of the mo-

tor, the load measurement is realised with a direct load

of the motor or alternatively with a partial load measure-

ment according to EN 61986 standards.

EMZ AKR motors during routine test Mill drive ASL 630-06 at the EMZ testing station

4,200 kW, 4,160 V, 60 Hz, 1190 rpm

Optimal quality assurance due to EMZ testing department

Quality Management & Acceptance Tests

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EMZ Cement special

04 EngineeringSolutions

Customised solutions in the cement industryThanks to our years of project experience in the cement

industry, we can offer you comprehensive technical ad-

vice and assistance for your drive solutions. From de-

velopment to construction, manufacture to operation,

we guarantee a standard of quality for our products and

service that will convince you of our expertise.

EMZ Engineering→ Project handling incl. installation, commissioning,

and training

→ 100% interchangeable replicas for existing motors

→ Customised constructions for special

drive solutions

→ Reduction of carbon brush wear-out

Fault analysis & Repairing of faults→ Examination of the plant on-site

→ Problem analysis

→ Supply of spare parts

→ Fault fixing & repair

Sleeve bearing reconstruction for hydrostaticsBy using a rotation-speed independent hydrostatic unit,

the rotor shaft in the bearing shell is lifted with a pres-

sure of 80 to 150 bar, thus ensuring a safe and wear-

and-tear-free operation at very low rotational speeds

and when starting up. The hydrostatic units can be con-

nected independently from a central oil lubrication unit

directly to the oil reservoir of the sleeve bearing.

Discussion with the plant’s engineers Inspection of the v ertical r oller m ill d rive on -site

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Other EMZ catalogues:→ EMZ Reference Catalogue

→ EMZ Image Brochure

→ EMZ Low-Voltage Motors’ Catalogue

→ EMZ High-Voltage Motors’ Catalogue

Catalogue requesteMail: [email protected]

Would you be interested in further EMZ catalogues?

If you are, please visit our website at www.emz.de.

All catalogues and references are available to download

in our “Download” section or as a printed edition.

Do you wish further information?

Please contact our specialists.

We are looking forward to hearing from you.

Phone: +49 2361 -6909 -0

You can find further information and complete contact

details for the respective product group on our website:

www.emz.de

Please visit our website and convince yourself of our va-

rious references.

EMZ cataloguesEMZ contact person

Contact & references

Ball mill Vertical roller mill

Contact & Catalogues

5,000 kWavailable from stock

Up to

EMZ Product Portfolio: Electric motors (for high and low voltage) → Three-phase squirrel cage motors up to 15,000 kW

→ Three-phase slipring induction motors up to 15,000 kW

→ DC motors up to 2,500 kW

Gear motors → Helical-gear motors

→ Worm-gear motors

→ Bevel-gear motors

Transformers (for high and low voltage) → Oil-filled transformers up to 20,000 kVA

→ Cast-resin transformers up to 6,000 kVA

→ Dry-filled transformers up to 1,000 kVA

Power electronics → Frequency converters

→ Inverters

Service → Maintenace & Repairs

→ Diagnosis

→ Testing department

Contact: Germany:

EMZ Elektro-Maschinen-Zentrale GmbH

Richardstrasse 70

45661 Recklinghausen, Germany

Phone: +49 2361 -6909 -0

Fax: +49 2361 -6909 -99

Web www.emz.de

eMail [email protected]

Switzerland:

EMZ Unitec AG

[email protected] | www.emz.ch

Phone: +41 52 633 42 42

France:

EMZ France Sarl

[email protected] | www.emz.fr

Phone: +33 (3) 89 62 79 09

11 | 2014

emz high-voltage motors & large drives

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