totally enclosed fan cooled high voltage cage induction motors moto… · totally enclosed fan...

Totally Enclosed Fan CooledHigh Voltage Cage Induction Motors

Flowpak Series

A REGAL-BELOIT COMPANY

M o t o r s f o r t h e L o n g R u n !

Flowpak 2 Flowpak 3

Phone:+91 9222 666 999Email:[email protected]:www.shopelect.com

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Flowpak motors are part of an integratedrange of induct ion machines,manufactured in a modern productionfacility dedicated to total quality.

Flowpak is a range of totally enclosedfan cooled cage induction motorsavailable horizontally or verticallymounted for connection to supplyvoltages up to 6.6 kV, outputsupto 800 kW.

The Flowpak2 range hasthree frame sizes withshaft heights 280, 315& 355 mm andFlowpak 3 range hasalso three framesizes with shaftcentre height 315,355 & 400 mm.Standard designs cover2 to 10 pole speeds andall sizes / speeds areall sizes/speeds areavailable with greaselubricated rolling element.

The MARATHON ElectricFlowpak range of inductionmachines has been availablefor many years and has beenwidely accepted throughout theworld for use in a wide rangeof arduous industries.

Design and operational features include :

High efficiency - upto 97% (For Flowpak 2) and 96% (Flowpak 3)

Low noise level (MSPL) - upto 85 dB (A) at 1 mt. distance with silencearrangements

Low stg. current - upto 550% for 4 Pole

High torque - 80% Voltage Starting on load "square low" drives

Short manufacturing cycle - 12 Weeks

High flexibility - detailed study of market requirements

Low Cost - Internationally Competitive.

A policy of continuous improvementhas allowed the machine to remaincompeti t ive in on aggressiveinternational market and the latestdevelopments described in thisbrochure will secure a future well intothe next century.

Flowpak 3


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Ratings & Per formancesFlowpak motors comply with therequirements of IEC 34-1, the relevantparts of BS4999 and BS5000, IS:325& other relevant Indian standards. Theyare designed for continuous dutycorresponding to Duty Type S1 of IEC34-1 and BS4999, part 101 section3, with a temperature rise by resistancenot exceeding 80K in a maximumambient temperature of 40°C. Thestandard rated outputs are taken fromthe R40 series of preferred numbersin accordance with the requirementsof clause 7 of BS4999 Part 101 andPart 1 of IEC 34-1. For enquiries withintermediate ratings the next highestpreferred rating will be offered andperformance data will be quotedaccordingly. This maximises the cost

and lead time benefits available fromthe range design

concept.

DimensionsDimensions are in accordance withBS4999 Part 141, IEC 72 and 72A.

Degree of Protection byEnclosureAll motors in the Flowpak range havea degree of protection IP55 ass tandard, conforming to therequirements of IEC 34-5, BS4999 Part105 & IS:4691. This is defined as dustprotected and suitable for operationin heavy seas (ships deck duty).

Method of CoolingThe standard of cooling form as definedwithin BS4999 Part 106, is IC 0141 -totally enclosed fan cooled. (Theequivalent IEC 34-6 nomenclature forthis enclosure type is IC411).

Forced ventilation (IC 416) is alsoavailable, suitable for constant torqueV.F.D. (690 V) application.

MountingMounting designations are inaccordance with IEC 34-7 Code 11and BS4999 Part 107. The standardmounting arrangements available onall frame sizes are.

IM1001 - Horizontal foot

IM3011 - Vertical flange

IM2001 - Horizontal foot and flange

SupplyStandard ratings are based on supplyvoltages of 3300 or 6600 volts on a50 Hz supply frequency and 2300 or4160 volts on a 60 Hz supplyfrequency. Other voltages andfrequency combinations one availableon request.

InsulationThe winding insulation system is classF in accordance with IEC 85 andBS2757. More detailed informationon insulation & Vacuum Pressure andImpregnation (VPI) systems/processesare available on request in a separatepublication entitled Resivac - The VPIinsulation system.

Special ApplicationsThe range design has been developedother considering many industrystandards and most requirements canbe met with the range standard plusstandard optional extras.

Standards and Specifications

50 Hz 60 Hz

800

600

400

200

VOLTAGE 3300 6600 3300 6600 3300 6600 3300 6600

POLES (REV/MIN) 2 (3000) 4 (1500) 6 (1000) 8 (750)

POWER OUTPUT

1000

KW

Flowpak 2


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Stator Frame and EndshieldsStator Frames and endshelds areproduced from high grade cast ironwith deep external cooling ribs.Spigotted Endshields are fitted to theframe and incorporate the bearinghousings.

Motor feet, terminal facings and twolifting eyebolt bosses are cast integralwith the frame. Horizontal frames alsohave jacking screw provision and pilotdowel holes as standard.

The Flowpak range of machines havepermanently fixed air gaps achievedby close tolerance machining of allcomponents.

BearingsThe standard bearing arrangementhas C3 internal clearance metric rollingelement bearings that are mounteddirectly into the bore of the endshield.Premium quality lithium based greasecontaining oxidation and corrosioninhibitors is used and pressure greaserelief facilities are a standard feature.All rolling element bearings have longrelubrication intervals and an L10bearing life of greater than 40,000hours.

Self contained or flow lubricated plainbearings can also be fitted if required.Flow lubricated plain bearings arefitted with inlet and outlet flanged stubpipes, for connection to an oil supplyprovided by others.

On vertically mounted motors the rotorweight is supported by the top bearingwhich would either be of the deepgroove ball or duplex type dependingon the axia l loading to beaccommodated.

All bearings used are of the highestquality produced by internationallyrecognised manufacturers ensuringspare parts are readily available. Aninsulated bearing arrangement canalso be provided on request.

Motor bearings have been selected onthe basis that the machines are directlycoupled, without external thrust beingimposed by the driven equipment. Ifthis is not the case then details shouldbe provided to allow appropriatedesign consideration.

Construction

Flowpak

Flowpak 2

Flowpak 3

FRAME POLES A B D E H HD AE C L*

2 457 710 75 140 280 1071 1067 190 1700

4-12 457 710 75 140 280 1071 1067 190 1700

2 508 800 75 140 315 1146 1102 216 1825

4-12 508 800 95 170 315 1146 1102 216 1855

2 610 900 75 140 355 1226 1142 254 2100

4-12 610 900 95 170 355 1126 1142 254 2130

DC280F710

DC315F800

DC355F900

Basic Dimensions of FLOWPAK-2 Motors

* L may be increased by 200 mm (approx) for silencer arrangement. Detail to beconfirmed after receipt of order.NOTE : All motors are with Antifrication rolling element bearings.


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Stator & Rotor CoresMachines have a laminated andinsulated sheet steel stator coreassembly, which is built on a mandreland welded under compression, beforefitting into the stator frame.

The rotor core made of laminated steelsheet is an interference fit on the shaft.The core is compressed betweenfabricated steel endplates and theassembly is then securely locked intoposition with a steel key ring.

Stator CoilsStator coils are formed from annealedcopper strip, insulated with mica. Loopsof the appropriate number of turns areformed, the coil straight portion isbonded and the loop is then pulled toshape. The coil is insulated with layersof mica tape, dependent on voltage,prior to the application of the finishingtapes.

Coil Connections and BracingThe coils are inserted in the slots, andfirmly wedged in position with epoxyglass or magnetic slot wedges.Endwindings are securely braced toprevent movement during service. Strictquality control is exercised during thewinding process.

FRAME POLES A B D E H HD AE C L*

2 508 800 75 140 315 1146 1102 216 1780

4-12 508 800 95 170 315 1146 1102 216 1810

2 610 900 75 140 355 1226 1142 254 2050

4-12 610 900 95 170 355 1126 1142 254 2080

2 686 1000 80 170 400 1336 1182 280 2330

4-12 686 1000 100 210 400 1336 1182 280 2370

DC315F3

DC35F3

DC400F3

Basic Dimensions of FLOWPAK-3 Motors

* L may be increased by 200 mm (approx) for silencer arrangement. Detail to beconfirmed after receipt of order.NOTE : All motors are with Antifrication rolling element bearings.


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The winding is high voltage tested atboth mains and high frequencyimmediately after the coils are insertedand wedged, and again afterconnecting. On completion of windingphase resistances and impedances arechecked for balance and conformancewith design.

ImpregnationFlowpak stators are Vacuum PresureImpregnated (VPI) with an epoxy resin.

The VPI system utilises materials witha minimum resin content at the windingstage, and places greater emphasison the final impregnation treatment.This not only extracts all air from thewinding, but also forces the resin,under pressure, into the interstices ofthe coils until they are totally filled. Allcoil packings retain a high proportionof resin and the connections becomeone consolidated ring after rotatecuring in time and temperaturecontrolled ovens.

Construction

Flowpak 2

Flowpak 3


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After impregnation the windings aresubjected to the voltage tests specifiedin BS4999 Part 101, section 9. Allmachines one subject to loss tangenttests.

Rotor BarsAll motors have copper or copper alloyrotor cages. Tight fitting rotor bars arebutt brazed to copper or copper alloyendrings. All rotors are dynamicallybalanced to more stringent levels thanthose specified in ISO2372. Overallmotor vibration severity does notexceed the limits specified in IS:12075.

ShaftsShafts are manufactured from carbonmanganese steel of grade 150M28 toBS970 or equivalent. Standard motorshave a single plain parallel shaftextension with a single keyway andmotors are balanced with a half keyfitted. The shaft extension is drilled andtapped in accordance with BS4999Part 141.

Fans & CowlsFlowpak 2 motors are fitted withunidirectional low noise level fansmanufactured from galvanised steel.Fan cowls are also manufactured from

steel. For Flowpak 3, one additionalinternal fan is used in place of wafterto get more thermal efficiency.

TerminationsUnless otherwise specified, motors aresupplied with a single fabricated steel,air insulated terminal box (for 3.3 kV)containing three mains terminalssuitable for direct-on-line starting. Thebox is mounted on the side of a topmounted adaptor and is supplied witha blank gland plate. Special glandscan be supplied to order. Phasesegregated terminal box is providedfor 6.6 kV Motors and for 3.3 kVMotors on request. A wide range ofalternative boxes are available.

When specified, access to thewinding neutral point can beprovided by removal of a steelcover or within a separateterminal box.

The prospective systemfault level should beadvised to enable selectionof the most suitable terminalarrangement.

AuxiliariesFlowpak 2 range allows the flexibilityof f i t t ing a wide var ie ty ofinstrumentation and auxiliariesincluding winding and bearingtemperature sensing elements, vibrationtransducers, anti-condensation heatersand silencing elements.

Separate ancillary terminal boxes canbe arranged on the top mountedterminal box adaptor.

Flowpak 2


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FacilitiesMARATHON Electric has implementedmajor restructuring of facilities. Thenew equipment together with theintroduction of upgraded CAD facilitieshas laid to significant reduction indelivery lead times.

Operational flexibility has alsoimproved and the introduction of'World Class' systems has enabled theCompany to introduce many productimprovements.

The recent res t ruc tur ing hastransformed the Kolkata Plant intodesignated production flow lines forH.T. and L.T. Products.

Upgradation of test facilities will enableus to test motors upto 4000KW, 11KV,4 pole.

The introduction of new facilities hasi m p r o v e d p r o d u c t i o n a n dmanufacturing effectiveness.

Manufacturing Facilities

Latest computer hardware & softwareavailable with Auto CAD facility in Designoffice.

Vertical press installed for accurate rotorcore building.

Air-conditioned dust free facility providedfor coil making and insulation taping.


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Dust free facility installed for Motor winding. Core Insertion Machine installed forinsertion of wound core into frame.

Spray painting booth

Vacuum Pressure & Impregnation Plant

Test Plant

Flowpak 2


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Paint SystemSurfaces are degreased then cleanedto ISO 8501 and ISO 8503, whichdefine surface cleanliness androughness.

Surfaces are then primed using amodified synthetic resin red oxideprimer to a dry film.

A single finish coat of two pack Epoxypaint is applied.

Total QualityThe complete range of HT Motors aremanufactured to a Quality Assuranceplan which lays down stringentacceptence norms for each stage ofproduction.

All materials are critically tested in-house to ensure the Flowpak 2 productrange meets National and Internationalstandards.

Customers are welcome to carry outstage inspection or final inspectionduring manufacture.

NoiseThe Flowpak range has been designedwith a low overall noise level. Usingspecial Silencer to meet a noise levelof 85 dB (A) at a distance of 1 mtr.

VibrationMotors in the Flowpak range including2 pole machines, meet the specifiedstandard of vibration of IS:12075.Rotors are dynamically balanced atmore or less rated RPM utilising twoplanes in areas of likely unbalance.Vibration is then checked on test at fullspeed and where a full test is requiredthis is done before during and afterthe heat run.

Enclosure ProtectionParticular attention has been paid toall sealing arrangements to ensurecompliance with the specifiedstandards. All machines in the rangehave IP55 protection as standrd.

One shot Rotor brazing Coil Testing Laboratory

Testing

Flowpak

Balancing M/C

CMM M/C


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NOTE


MEM

I/C

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FLO

WPA

K/11

08/0

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RMG

–LTM

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TC 0

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2008

Specialized custom built motors • Specialists in short cycle deliveries

Marathon Electric Motors (India) Ltd. Registered & Head Office: 58, Taratala Road, Kolkata - 700024. LT Motor & Fan Factory, Paharpur Works, 58,Taratala Road, Kolkata - 700024, Fax: 2469 5369 / 8530, Phone : 09903900801. Large LT Motor & HT Motor Factory, AEI Works 1, Taratala Road,Kolkata- 700024. Marathon Regional Offices: New Delhi: 708, Eros Building, 56, Nehru Place; Tel: 011 4160 7123, 09313290402. Chandigarh:Chamber No. 8a, 2 Floor, Sco No. 2441-42, Sector 22-C; Tel: 09316102451. Mumbai:114 Navneelam, R.G. Thadani Marg, Worli; Tel: 022 32659844, 09322645753, Fax: 022 3040 1555. Pune: 41/14, Office Club Swaroop Complex Karve Road; Tel: 020 2546 3978, 09371025388. Ahmedabad:415 / Platinum Plaza, Nr. Pushkar Tower, Judge-bunglow-bodakdev Road; Tel: 079 2560 2297, 09327048567. Nagpur: 1 Floor, Block A, ThaparEnclave, Plot No. 148, Ramdaspeth; Tel: 0712 2526 220, 09373283527. Raipur: 1 Floor, 141, Sundernagar, Near Adarsh Chowk; Tel: 0771 2210240. 09329128913. Chennai : Door No. 9, Flat No. 7, 1 Floor, Thiru. Vi. Ka. Road, Royapettah, (opp, Sathyam Theatre), Tel: 044 4351 0152,09382102392, Fax: 044 4351 0153. Secunderabad: Cabin No. 47, 303, Swapnalok Complex, 92, S. D. Road; Tel: 040 2781 2724, 09391340619.Bangalore : C1-101, White House, 15 Cross, 6 Main R. T. Nagar; Tel: 080 2655 8729, 09341279429. Bhubaneswar : C/o. Plot No. 16-b, EngineersColony, Old Station Bazar; Tel: 0674 231 3744, 09338212907. Jamsbedpur: C/o. Mr. D. P. Ghosh, House No. 7, Bidyasagar Path, Uliyan, Kadma;Tel: 0 93346 12014. Marathon Electric India Pvt. Ltd., Sec.-11 Model Town, Faridabad - 121006 (INDIA), Tel: 0129 2286421/2265340; Fax : 0129-2284855, email : [email protected] GEMI Regional Offices : Ahmedbad : 406, Vedant Complex, 7, Kalpana Colony, Off. C.G. Road,Navrangpura, Ahmedabad-380009, Tel: 079-26561819, 9825611502. Fax: 079-26560452. Chennai : 6 Arcot Road, Vadapalani, Chennai - 600092,Tel: 044-42136697, 42333353, 9840429331, Fax: 044-42082322. Jaipur : C/o Flat No. 104, Block A, Rama Heritage Apartments, Central Spine,Vidhyadhar Nagar, Jaipur-302 023. Ph: 9982655661. Kolkata : 58, Taratala Road, Kolkata - 700024; Tel: 91 033 24695560/61, Fax: 03324695369/8530. Mumbai : B-908/909, Sagar Tech Plaza, Andheri - Kurla Road, Saki Naka, Andheri (East), Mumbai - 400072, Tel: 022-28523106,9833756269, Fax: 022-28528938. Pune : C/o: 8, Sethu Apartments, Right Bhusari Colony, Paud Road, Kothrud, Pune-411038, Tel: 020-65224846,9960604846. Bangalore : Tel:9342299995. Hyderabad : Tel:9393002665. Delhi : Flat No. 516-518, 5th Floor, Antriksh Bhawan, 22 K.G. Marg NewDelhi -01 Tel: 9873184209.

A REGAL-BELOIT COMPANY


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