Technical Guidelines

ABB LT Motors
Contents

Product range 3 Others

Features of standard TEFC motors 3
Manufacturing range summary 3 Testing 30
Designs variants 4 Motor for frequency converter drive 31
Features of standard SPDP motors 4 Guide and check points for motor selection
(mechanical aspects) 33
General Guide and check points for motor selection
(electrical aspects) 34
Standards 5 Ordering Information 35
Tolerances 6 Frequently asked questions 37
Mounting arrangement 6
Degree of protection 8
Cooling methods 9
Direction of rotation 9
Insulation and insulation class 9
Effect of voltage and frequency variation 10
Permitted output in high ambient temperature
and high altitudes 10
Permitted output for voltage unbalance 10
Motors for 60 Hz operation 11
Winding connection 12

Electrical

Electrical features 13
Starting method for AC motors 14
Typical motor current and torque curves 15
Comparison between starting methods 15
Starting time 16
Example of starting performance with
different load torques 17
Electrical braking 18
Duty types 20
Protection accessories 22
Guide for fuse protection 22
Voltage drop along cable 23
Negative sequence withstand characteristics 23
Power factor improvement chart 24

Mechanical

Mechanical Features 25
Exploded view of HX motors 26
Pulley diameter 27
Permissible radial forces 28
Permissible axial forces 29
Product Range

! Standard TEFC motor, IS : 325 - 1996

! Crane duty motors
! Non sparking motors Type “EX-n”
! Increased Safety motors Type “Ex-e”
! Flame proof motors Type “Ex-d”
! Variable frequency drive motors
! Ring frame motors, IS : 2972 Part III
! Roller table motors for steel plants
! Auxiliary motors for a.c locomotives
! Custom build motors for textile, machine tools and various other applications.
! Standard SPDP motors, IS : 325 - 1996

Feature of standard TEFC Motors

Type Three phase squirrel cage induction motor

Enclosure Totally - enclosed fan cooled
Voltage ± variation 415V ± 10%
Frequency ± variation 50Hz ± 5%
Combined variation 10% (Absolute Sum)
Mounting reference As per IS 4691
Frame dimensions As per IS 1231; IS 2223
Altitude Up to 1000 M
Relative humidity Up to 100%
Degree of protection IP55
Class of insulation Class F
Ambient temperature / temperature rise 45ºC/75ºC Up to Frame 160
50ºC/70ºC Frame 180 to 400
Duty S1/Continous
Position of terminal box Top at drive end
Connection / No of leads Up to 2 HP - STAR / 3 Leads > 2 HP - DELTA / 6 Leads
Direction of rotation Bi-directional
Grease type Lithium complex grease
Greasing arrangements Online greasing arrangement for 225 and above
Cooling IC 0141 (TEFC)
Paint Polyurethane (Shade: Munsell Blue)

Range
Output 0.18 ...500kW; 0.25 ...675hp; according to IS 325
Voltage 220 ... 660V
Frequency 25 ... 60Hz
Duty S1 ... S8 according to IS:325
Ambient Temperature -20ºC ... 65ºC

3
Design Variants

Electrical Mechanical
Non standard voltage and frequency variations Non standard mounting dimensions
AC variable speed drives Special shaft extension
High torque motors Double shaft extension
High slip motors Separately ventilated motors
Motors for frequent start / stops / reversals Low vibration and noise level
Frequency 25 to 60 Hz Brake motors
Special performance requirements Special bearings and lubrications
Class H insulation Tacho mounting / SPM mounting
Voltage 220V to 550V Non standard paint shade
Alternative terminal box position
IP 56 protection
Special shaft material
Special size of terminal box and terminal arrangements
Surface cooled motors
SS name plate
Non standard keyway
Epoxy gelcoat on overhangs
Space heaters
Thermistors, RTD , BTD
Single compression / double compression glands

Note: Please refer to the company for details of special designs offered.

Feature of standard SPDP Motors

Type Three phase squirrel cage induction motor
Enclosure Screen protected drip proof
Voltage ± variation 415V ± 10%
Frequency ± variation 50Hz ± 5%
Combined variation 10% (Absolute Sum)
Mounting reference As per IS 4691
Frame dimensions As per IS 1231; IS 2223
Altitude Up to 1000 M above MSL
Relative humidity Low / indoor applications
Degree of protection IP 23
Class of insulation F, Temperature rise limited to CL.B
Ambient temperature 40ºC
Duty S1
Position of terminal box Top
Connection / No of leads DELTA / 6 Leads
Direction of rotation Bi-directional
Grease type Li-complex grease
Cooling IC 01
Paint Polyurethane (Shade: Munsell Blue)

4
Standards

ABB Motors are designed to ensure that performance complies with IS:325. HX/M2BA Motors are totally-enclosed three-phase
squirrel cage type complying with relevant Indian Standards.

List of Indian Standards applicable to low-voltage induction motors are as given below:

IS No. Title

IS 325:1996 Three-phase induction motors (fifth revision)

IS 900:1992 Code of practice for installation and maintenance of induction motors (second revision)

IS 1231:1974 Dimensions of three-phase foot-mounted induction motors (third revision)

IS 2223:1983 Dimensions of flange mounted a.c. induction motors (first revision)

IS 2253:1974 Designation for types of construction and mounting arrangement of rotation electrical machines
(first revision)

IS 2254:1985 Dimensions of vertical shaft motors for pumps (second revision)

IS 2968:1968 Dimensions of slide rails for electric motors

IS 4029:1967 Guide for testing three-phase induction motors

IS 4691:1985 Degrees of protection provided by enclosure for rotation electrical machinery (first revision)

IS 4722:1992 Rotating electrical machines (first revision)

IS 4728:1975 Terminal marking and direction of rotation for rotating electrical machinery (first revision)

IS 4889:1968 Method of determination of efficiency of rotating electrical machines

IS 6362:1971 Designation of methods of cooling of rotating electrical machines

IS 7538:1975 Three-phase squirrel cage induction motors for centrifugal pumps for agricultural applications

IS 7816:1975 Guide for testing insulation resistance of rotating machines

IS 8151:1976 Single-speed three-phase induction motors for driving lifts

IS 8223:1976 Dimensions and output ratings for foot-mounted electrical machines with frame numbers 355 to 1000

IS 8789:1978 Values of performance characteristics for three-phase induction motors

IS 12065:1987 Permissible limits of noise level for rotating electrical machines

IS 12066:1987 Three-phase induction motors for machine tools

IS 12075:1986 Mechanical vibration of rotating electrical machines with shaft heights 56mm and higher-measurement,
evaluation and limits of vibration severity (super ceding IS 4729:1968)

IS 12615:1989 Energy efficient three-phase squirrel cage induction motors

IS 12802:1989 Temperature rise measurement of rotating electrical machines

IS 12824:1989 Type of duty and classes of rating assigned to rotating electrical machines

IS 13107:1991 Guide for measurement of winding resistance of an a.c. machine during operation at alternating voltage

IS 13529:1992 Guide on effects of unbalanced voltages on the performance of three-phase cage induction motors

IS 13555:1993 Guide for selection and application of three-phase a.c. induction motors for different types of driven
equipment

5
Tolerances (as per IS:325-1996)

Item Tolerance

Efficiency (h)

By summation of losses
Motors up to 50kW -15 percent of (1 - h)
Motors above 50kW -10 percent of (1 - h)

By input output method -15 percent of (1 - h)

Total losses applicable to motors above 50kW* +10 percent of total losses

Power factor (cosf) -1/6 of (1 - cosf) min 0.02 and max 0.07

Slip at full load and working temperature ±20 percent of the guaranteed value

Breakaway starting current with the specified ±20 percent of the guaranteed starting current
starting method (no negative tolerance)

Breakaway torque -15 to +25 percent of the guaranteed torque

(+25 percent may be exceed by agreement)

Pullout torque -10 percent of the guaranteed torque except that after
applying this tolerance, the torque shall not be less than
1.6 or 1.5 times the rated torque

Moment of inertia or stored energy constant for ±10 per cent of the guaranteed value
motors above 315 frame

* Upon agreement between manufacturer and purchaser

Mounting arrangements
IS:2253 and technically identical IEC 60034-7 specify two
possible ways of describing how a motor is mounted.

Code I covers only motors with bearing end shields and one
shaft extension. The code consists of letters IM, a further letter
and a number.

Code II is a general one applicable to all rotating machines. The

code consists of letters IM and four characteristics numerals as
illustrated below.

IM 1 00 1

Shaft extension, one cylindrical shaft extension

Mounting arrangement, horizontal mounting with

feet downward

Type of construction, foot mounted motor with

two endshield

International mounting

6
Mounting arrangements

CodeI/CodeII

Foot-mounted motor, IM B 3 IM V 5 IM V 6 IM B 6 IM B 7 IM B 8
IM 1001 IM 1011 IM 1031 IM 1051 IM 1061 IM 1071

Flange -mounted motor, IM B 5 IM V 1 IM V 3

Large flange IM 3001 IM 3011 IM 3031 IM 3051 IM 3061 IM 3071

Flange -mounted motor , IM B 14 IM V 18 IM V 19

Small flange IM 3601 IM 3611 IM 3631 IM 3651 IM 3661 IM 3671

Foot and flange-mounted, IM B 35 IM V 15 IM V 36

Motor with feet, IM 2001 IM 2011 IM 2031 IM 2051 IM 2061 IM 2071
Large flange

Foot and flange-mounted, IM B 34

Motor with feet, IM 2101 IM 2111 IM 2131 IM 2151 IM 2161 IM 2171
Small flange

Foot-mounted motor, IM 1002 IM 1012 IM 1032 IM 1052 IM 1062 IM 1072

Shaft with free extensions

7
Degree of protection

Degree of protection for rotating machines are indicated according to IS:4691 using the characteristic letters ‘IP’ followed by two
characteristic numerals for the degree of protection.

The first numeral indicates protection against contact and ingress of foreign bodies.

The second numeral indicates protection against ingress of water.

First characteristic numeral

IP 2 Protected against solid objects greater than 12mm

IP 5 Dust protected motors, Ingress of dust is not fully protected, but dust can not enter in an amount sufficient to interface with
satisfactory operations of the motor.

Second characteristic numeral

IP 3 Protected against spraying water, sprayed up to angle of 600 from vertical shall have no harmful effect.

IP 5 Protected against water, jets by a nozzle from any direction shall have no harmful effect.

IP 6 Protected against heavy seas, powerful jets from all direction shall have no harmful effect.

Degree of protection - Schematic

1st Numeric 1st Numeric

0 No protection 0 No protection
1 Protected against 1 Dripping water
solid objects shall have no
greater that 50mm harmful effect.
(e.g. hand)

2 Protected against 2 Protected against

solid objects dripping water
greater that 12mm when enclosure is
(e.g. fingers) titled 150

3 Protected against 3 Protected against

solid objects spraying water up
greater that 2.5mm to 600
(e.g. tools,
wires)

4 Water splashed
4 Protected against from any direction
solid objects shall have no
greater that 1mm harmful effect
(e.g. wire or
strips)

5 Water hosed
5 Ingress of dust is against the
not totally enclosure shall
protected, but does have no harmful
not enter in effect (water jets)
sufficient quantities
to harm equipment

6 Water from
6 No ingress of dust powerful jets of
heavy seas shall
have no harmful
effects

8
Cooling Methods D-end and N-end
Cooling methods of HX/M2BA Motors are in accordance with The ends of motors are defined as D-end; the end that is
IS:6362. The motors are cooled by the method IC 0141, i.e. normally the drive end of the motor and N-end; the end that is
frame surface cooled, with external cooling fan on motor shaft. normally the non-drive end of the motor.

The fan is made of strong engineering plastic for frames upto

200 (aluminum alloy/cast iron option is also available). For
Direction of rotation
frames 225 and above, aluminum alloy fans are used. Fans of
all motors are bidirectional. The motors are provided with In conformation with IS:4728, the terminals of the motor are
cooling ribs for increased surface area and improved cooling. marked such that when the alphabetic sequence of the
An air gap is left between ribs and fan cover for cleaning terminals U1, V1, W1: U2, V2, W2 corresponds to the supply
purposes. The ribs are designed so that they keep the flow of phase sequence L1, L2, L3 the motor runs in a clockwise
air close to the surface of the motor along the entire length, thus direction, when seen from drive end.
improving self cleaning and cooling.
For anticlockwise operation of the motor, any two of the supply
The external ventilation of the motors is obtained by means of phase connections (L1, L2, L3) are exchanged to obviate the
the fan mounted to the shaft, which sucks in the ambient air need for change of the terminal markings.
through the fan cover on the N-end and blows it over the frame
in between the ribs. Fans are axially and radially locked to
prevent vibration. The internal cooling of motors is affected by
the churning action of internal air by the ribs on the die-cast
rotor.

0
C

Insulation and insulation classes 180

15
Insulation materials are divided into insulation classes. Each 155
class has a designation corresponding to the temperature that 15
is the upper limit of the range of application of the insulating
material under normal operating conditions.
130 Hotspot temperature
margin 10
The winding insulation of a motor is determined on the basis of 120
the temperature rise in the motor and the ambient temperature.
75 95 120
The insulation is normally dimensioned for the hottest point in
the motor at its normal rated output and an ambient Permissible temperature
rise
temperature of 45ºC/50ºC. Motors subjected to ambient
temperatures above 45ºC/50ºC will generally have to be
derated.
In most cases, the standard rated outputs of motors from ABB 45
motors are based on the temperature rise for insulation class B. Maximum ambient
45 45 45
temperature
Where the temperature rise is according to class F, this is
specified in the data tables. Insulation class
Maximum winding B F H
temperature 130 155 180
However, all the motors are designed with class F insulation,
which permits a higher temperature rise than class B. The
Temperature limits are according to standards. The extra
motors, therefore, have a generous overload margin. If
thermal margin when using class F insulation with class B
temperature rise to class F is allowed, the outputs given in the
temperature rise makes the motors more reliable.
tables can be increased by approximately 12%.

9
Effect of voltage and frequency variation

Almost without exception, the starting current decreases slightly more in proportion to the voltage. Thus for example 90% of rated
voltage the motor will draw slightly less than 90% of the starting current, approximately 87 to 89%. The starting torque is
proportional to the square of the current, the torque delivered at 90% of rated voltage is therefore only 75% to 79% of the starting
torque. Particular attention should be paid to these points if the electrical supply is weak and when starting techniques based on
current reduction are being used. The pull out torque is roughly proportional to the voltage.

If the saturation of the magnetic circuit is neglected, then the general effect of variation in voltage and frequency on the
characteristics of induction motor can be given as per the table below.

Table - Effect of variation of voltage and frequency on the characteristics of induction motor*

Characteristics Voltage Frequency

110% 90% 105% 95%
Torque Increased by 21% Decrease 19% Decrease 10% Increase 11%
Starting & maximum
Speed
Synchronous No change No change Increase 5% Decrease 5%
Full load Increase 1% Decrease 1.5% Increase 5% Decrease 5%
Slip Decrease 17% Increase 23% Little change Little change
Current
Rated Decrease 7% Increase 1% Slight decrease Slight increase
Starting Increase 10-12% Decrease 10-12% Decrease 5-6% Increase 5-6%
No load Increase 10-15% Decrease 10-15% Decrease 5-6% Increase 5-6%
Overload capability Increase 21% Decrease 19% Slight decrease Slight increase
Temperature rise Decrease 3-4% Increase 6-7% Slight decrease Slight increase
Magnetic noise Slight increase Slight Decrease Slight decrease Slight increase
Efficiency, full load Increase 0.5-1.0% Decrease 2% Slight increase Slight decrease
Power factor, full load Decrease 3% Increase 1% Slight increase Slight decrease
*These variations are indicative in nature and are not uniformly applicable to all the designs.

Permitted output in high ambient temperature and high altitudes

Motors of basic design are intended for operation in a maximum ambient temperature of 45°C and at maximum altitude of 1000
meters above mean sea level. If a motor is to be operated in higher ambient temperature or at higher altitude, it should normally be
derated according to the following table.

Ambient temperature (°C) 40 45 50 55 60* 65* 75* 85*

Permitted output (% of rated output) 107 100 96.5 93 90 86.5 79 70

Height above sea level (M) 1000 1500 2000 2500 3000 3500 4000
Permitted output (% of rated output) 100 96 92 88 84 80 76

*changes in the type of lubricant and lubrication interval required.

Permitted output for voltage unbalance

The phase unbalance for voltage is calculated as follows:
maximum difference in voltage compared to average voltage value
% voltage imbalance = 100 x _____________________________________________________
average voltage value
If this unbalance is known before the motor is purchased it is advisable to apply derating as per following table.
Unbalance 1% 2% 3% 4% 5%
Derating 100 95 90 83 76

Rerating S1 duty motors to S2 and S3 duty motors

Standard motors can be used for S2 and S3 duties with increased outputs. However, the starting torque and pull out torque as a
percentage of the full load torque would be reduced.

S2 S3

60 min 30min 10min 60% CDF 40%CDF 25% CDF

100% 115% 120% 100% 105% 120%

10
Motors for 60 Hz operation

Motors wound for a certain voltage at 50 Hz can be operated at 60 Hz, without modification, subject to the following changes in their
data.

Motor Connected Data at 60 Hz in percentage of values at 50Hz

wound for to 60 Hz
50 Hz and and Output rpm IN IS/IN TN TS/TN Tmax/TN1)

220 V 220 v 100 120 98 83 83 70 85

225 v 115 120 100 100 96 95 98

380 V 380 V 100 120 98 83 83 70 85

415 V 110 120 98 95 91 85 93
440 V 115 120 100 100 96 95 98
460 V 120 120 100 105 100 100 103

400 V 380 V 100 120 100 80 83 66 80

400 V 100 120 98 83 83 70 85
415 V 105 120 100 88 86 78 88
440 V 110 120 100 95 91 85 93
460 V 115 120 100 100 96 95 98
480 V 120 120 100 105 100 100 100

415 V 415 V 100 120 98 83 83 70 85

460 V 110 120 98 95 91 85 94
480 V 115 120 100 100 96 95 98

500 V 500 V 100 120 98 83 83 70 85

550 V 110 120 98 95 91 85 94
575 V 115 120 100 100 96 95 98
600 V 120 120 100 105 100 100 103

Efficiency, power factor and temperature rise will be approximately the same as at 50 Hz.

1) IN = rated current
IS/IN = starting current/rated current
TN = rated torque
Tmax/TN = maximum torque/rated torque
TS/TN = starting torque/rated torque

11
Winding Connection

Single speed
Star connected windings for motors upto 2 hp and delta connected windings for motors above 2 hp are standard features. The
connection diagrams for single speed motors are given below:

D - connection Y - connection

Double speed
The difference in winding configuration and application necessitates different winding connections so as to accommodate maximum
power in a given frame.
- Motors with two separate windings are normally Y/Y connected upto frame size 160, larger motors are D/D, Y/D or D/Y
connected
- Motors with Dahalander connection, are in D/YY when they are designed for constant torque drives and Y/YY when they are
designed for fan drive.

The connection diagram for different combinations are given below:

1. Two separate
windings Y/Y

Low speed High speed Low speed High speed

2. Two separate
windings D/D

Low speed High speed Low speed High speed

3. Dahlander-
connection D/YY

Low speed High speed Low speed High speed

4. Dahlander-
connection Y/YY

Low speed High speed Low speed High speed

12
Electrical features
1. Voltage
Rated voltage is the voltage between line terminals for
which the motor is designed.
Standard voltage for motors is 415V. Motors can, however,
be made available for any supply voltage between 220V
and 660V. Motors for two different supply voltages have
non standard windings and are available on request.
2. Frequency
Rated frequency is the frequency of the voltage for which
the motor is designed.
The basic design of the motor is suitable for a rated supply
frequency of 50 Hz. HX/M2BA motors can be offered for
any frequency in the range 25 Hz to 60 Hz, however, for
supply frequency other than 50 Hz, they are made
available on request.
3. Voltage and frequency variation
Motors can be operated continuously at rated output, with a
long term voltage variation of ±10%, frequency variations of
±5% and a combined voltage and frequency variation of
10%, over rated values. The temperature rise may increase
by 10K at extreme voltage and frequency.
If the motors are required to operate continuously at
voltage approaching the limits of voltage tolerances without
exceeding the temperature rise limit, this must be specified
at the time of enquiry.
4. Number of poles
Number of poles of the motor determine the basic speed
(synchronous speed) of the motor. Standard motors are
available in the configuration of 2,4,6 and 8-poles.
5. Power
Rated power is the shaft power of the motor with an
ambient temperature not exceeding 45°C/50°C and an
altitude not exceeding 1000m above mean sea level.
6. Rated speed, slip
Rated speed corresponds to the operating speed of the
motor at the rated power when it is being fed at rated
voltage and frequency.
The synchronous speed of an induction motor depends on
the supply frequency and the number of poles of the stator
winding. Thus,
f
hs= x 60(rpm)
p
where hs= synchronous speed (rpm)
f = frequency (Hz)
p = number of pair of poles
note 2p = number of poles
The rated speed given in the list is for motors operating at
rated power under normal voltage and frequency.
The difference between synchronous speed, hs and rotor
speed, n; referred to the synchronous speed, is called slip.
This slip, s, is expressed as a percentage;
hs - h
s= x 100 (%)
hs
When the motor is partly loaded the slip varies almost
linearly with the load.
7. Rated current
It is the value of the current taken by the motor when
delivering rated power at rated voltage and frequency. The
value of rated currents are at specified voltage, for other
voltages, Ux, the current Ix may be calculated as:
415.I
Ix =
Ux
Where Ux = new voltage
Ix = new current
I = current at 415V
The current consumption varies also with the loading of the
motor, but it should be noted that the relationship is not
linear.
8. Starting current
Usually, given as a percentage or as a multiple of rated
current, it is the value of the current drawn by the motor
during starting. The value of the starting current is generally
between 500-700% (5-7 per unit) of the rated current.
9. Torque characteristics
Typical torque/speed characteristics of the motor is shown
in figures on page no. 15 along with different relevant
parameters.
The nominal torque of the motor TN' is the torque developed
by the motor at rated speed, n while delivering rated power
P. The relationship between the torque TN' the power P, and
the speed n is
415.I
TN= 9550 x [Nm]
Ux
Where P = power (kW)
n = motor speed (rpm)
alternatively, torque T, in kgm can be given as
P
TN= 974 x [kgm]
n
Starting torque of the motor TS' is the torque developed by
the motor at zero speed when it is directly switched on.
Value of starting torque is usually given as a percentage or
as a multiple of nominal motor torque TN.
Pull out torque of the motor Tmax' is the maximum torque that
the motor can develop when it is operated directly on line.
Value of pull out torque is usually given as a percentage or
as a multiple of nominal motor torque TN.
10. Moment of inertia
The moment of inertia J is given in Kgm2. The moment of
inertia is numerically equal to 1/4 GD2. The moment of
inertia JL of the driven machine at nL rpm when referred to
motor speed n rpm is given by
J = JL [nL/n]2
11. Overloads
In accordance with IS:325 motors are rated to withstand an
overload, an excess torque of 60% of their rated torque at
rated voltage and frequency for 15 seconds.
13
Starting methods for AC motors

Reducing electrical and mechanical stress at start-up

The starting current of an AC motor can vary from 3 to 7 times the nominal current. This is because a large amount of energy is required to
magnetise the motor enough to overcome the inertia the system has at standstill. The high current drawn from the network can cause
problems such as voltage drop, high transients and in some cases, uncontrolled shutdown. High starting current also causes great
mechanical stress on the motor’s rotor bars and windings and can affect the driven equipment and the foundations. Several starting
methods exist, all aiming to reduce these stresses. The load, the motor and the supply network determine the most appropriate starting
method. When selecting and dimensioning the starting equipment and any protective devices, the following factors must be taken into
account:

• The voltage drop in the supply network when starting the motor
• The required load torque during start
• The required starting time

Direct-on-line (DOL) start:

UN
Direct on line starting is suitable for stable supplies and mechanically stiff and well dimensioned Ist
systems. It is the simplest, cheapest and most common starting method. Starting equipment for
small motors that do not start and stop frequently is simple, often consisting of a hand operated UN = Rated net
motor protection circuit breaker. Larger motors and motors that start and stop frequently, or have voltage
some kind of control system, normally use a direct-on-line starter which can consist of a contactor Ist = Start current
plus overload protection, such as a thermal relay. at full voltage

Star-Delta (Y/D) starting:

UN
Most low voltage motors can be connected to run at either 400V with delta connection or at 690V
with star connection. This flexibility can also be used to start the motor with a lower voltage. Ist
Star/delta connection gives a low starting current of only about one third of that during direct-on- UN = Rated net
line starting, although this also reduces the starting torque to about 25%. The motor is started with voltage
Y-connection and accelerated as far as possible, then switched to D-connection. This method can
only be used with induction motors delta connected for the supply voltage. Ist = Start current
at full voltage

Soft starters
UN
Soft starters are based on semiconductors, which, via a power circuit and a control circuit, initially IstR
reduce the motor voltage, resulting in lower motor torque. During the starting process, the soft UN = Rated net
starter progressively increases the motor voltage so that the motor becomes strong enough to voltage
accelerate the load to rated speed without causing torque or current peaks. Soft starters can also IstR = Start current
be used to control the stopping of a process. Soft starters are less costly than frequency converters at red. voltage
but like frequency converters, they may inject harmonic currents into the grid, disrupting other UM
processes. UM = Motor voltage

Frequency converter start UN

IstR
Although a frequency converter is designed for continuous feeding of motors, can also be used UN = Rated net
exclusively for start-up only. The frequency converter enables low starting current because the voltage
motor can produce rated torque at rated current from zero to full speed. As the price of frequency IstR = Start current
converters continues to drop, they are increasingly replacing soft starters. However in most cases UM at red. voltage
they are still more expensive than soft starters, and like these, they inject harmonic currents into UM = Motor voltage
the network.

14
Typical motor current and torque curves

TM = Motor torque Tmax = Breakdown torque or pull-out torque

TMD = Motor torque with direct-on-line starting Tacc = Acceleration torque
TMY = Motor torque with start-delta starting I = Current
TL = Load torque IN = Rated current
TL0 = Load breakaway torque ID = Current in D-connection
TN = Rated motor torque IY = Current in Y-connection
TS = Breakaway torque or locked rotor torque n = Speed
Tmin = Pull-up torque nS = Synchronous speed

Comparison between starting methods

Current Torque

1 = Direct-On-Line starter
2 = Y/D-starter
3 = Start with soft starter

15
Starting time

Theory If only the starting torque and maximum torque of the motor and
the nature of the load are known, the starting time can be
The starting current of an induction motor is much higher than approximately calculated with the equation:
the rated current, and excessively long starting period causes K1
harmful temperature rise in the motor. The high current also Tst = (JM + JL) x
Tacc
leads to electro-mechanical stresses. It is, therefore, of
importance to know the time taken by the motor to accelerate where Tst = starting time
the load to rated speed. This time is called starting time or Tacc = acceleration torque as per diagrams, Nm
acceleration time. K1 = as per table below

Starting time depends upon: Speed Poles Frequency

Constant 2 4 6 8 10 Hz
- Total inertia of the system nM 3000 1500 1000 750 600 50
- Torque speed curve of the motor K1 345 157 104 78 62
- Torque speed curve of load
nM 3600 1800 1200 900 720
50
If the torque curves for the motor and the load are known, the K1 415 188 125 94 75
starting time can be calculated by integrating the equation:

¶w This method of calculation may be used for direct-on-line

T - TL = (JM + JL) x
¶t starting and for motors up to about 250kW. In other cases more
points on the motor torque curves are required. In any case up
where T = Motor torque, Nm
to the point of maximum torque.
TL = Load torque, Nm
JM = Moment of inertia of motor, kgm2
JL = Moment of inertia of load, kgm2 If there is speed transformation between the motor and the
driven machine, the load torque must be recalculated for the
W = Motor angular velocity
motor speed, by using the following formula:

TL x nL
TL' = nM

where TL' = Recalculated load torque, Nm

nM = Motor speed, rpm
nL = Load speed, rpm

The moment of inertia must also be recalculated.

JL'=JL' x (nL/nM)2

where JL'= Recalculated moment of inertia, kgm2

16
Example of starting performance with different load torques

4-pole motor, 160 kW, 1475krpm

1
TL = 1600 x = 800 Nm at nM rpm
Torque of motor: 2
TN = 1040 Nm, Moment of inertia of load:
TS = 1,7 x 1040 = 1768 Nm nM
Tmax = 2,8 x 1040 - 2912 Nm JL = 80 kgm2 at nL = rpm
2
1
Moment of inertia of motor: JM = 2,5 kgm2 JL = 80 x ( ) 2 = 20 kgm2 at nM rpm
2
The load is geared down in a ration of 1:2 Total moment of inertia:

Torque of load: JM + JL at nM r/min

nM
TL = 1600 Nm at nL = rpm 2,5 + 20 = 22,5 kgm2
2

Example 1: Example 3:

Lift motion Fan

Torque Torque

TL TL

Speed Speed

TL = 1600 Nm T'L = 800 Nm TL = 1600 Nm T'L = 800 Nm

Constant during acceleration Square-law increase during acceleration

1
Tacc = 0,45 x (TS + Tmax) - T'L Tacc = 0,45 x (TS + Tmax) - x T'L
3
1
Tacc = 0,45 x (1768 + 2912) - 800 = 1306 Nm Tacc = 0,45 x (1768 + 2912) - x 800 = 1839 Nm
3
K1 K1
tst = (JM + J'L) x tst = (JM + J'L) x
Tacc Tacc
157 157
tst = 22,5 x 1360 = 2,7 s tst = 22,5 x = 1,9 s
1839

Example 2: Example 4:

Piston pump Fly wheel

Torque Torque

TL TL

Speed Speed

TL = 1600 Nm T'L = 800 Nm TL = 0

Linear increase during acceleration Tacc = 0,45 x (TS + Tmax)

1
Tacc = 0,45 x (TS + Tmax) - T'L Tacc = 0,45 x (1768 + 2912) = 2106 Nm
2
1 K1
Tacc = 0,45 x (1768 + 2912) - €800 = 1706 Nm tst = (JM + J'L) x T
2 acc
K1
tst = (JM + J'L) x T 157
tst = 22,5 x = 1,7 s
acc 2106
157
tst = 22,5 x 1706 = 2,1 s

17
Electrical braking

Countercurrent braking (Plugging) For slip-ring motors the starting and braking times are both
determined by the dimensioning of the rheostatic starter.
With countercurrent braking, an ordinary standard motor is
switched at full speed for the opposite direction of rotation. This
can be done with a reversing switch. After braking to a Torque Torque
standstill, the motor starts in the opposite direction of rotation,
unless the current is switched off at the right moment. A low
speed detector is therefore used to cut off the supply to the
motor when the speed approaches zero.

Countercurrent braking gives a very high braking torque. The Mb

Acceleration torque
current during braking is about the same as during starting, so Braking torque
that there is a considerable temperature rise in the motor.
Consequently the permitted frequency of braking with the
countercurrent technique is only about one-quarter of the
number of permitted braking can easily be exceeded with Speed
countercurrent braking, temperature sensors should always be
used to protect the motor windings from overheating.
Countercurrent braking Starting
The permitted number of counter current braking can be
calculated approximately with the formula:
Figure 1
2
P2 (In this case the load torque contributes to the braking torque.
3600x P1 To be on the safe side, however, calculations are based on the
braking torque being the same as the acceleration torque.)
X= 2 2
Ist P2
4x - P1
Tbx I

Torque Torque
where x = Permitted number of brakings per hour
P2 = Output taken from motor, kW
P1 = Rated output of motor in continuous duty, kW
tb = Braking time, s
Ist/I = Starting current / full load current

For squirrel cage motors the braking time can be calculated Braking torque Acceleration torque
approximately with the formula:

K1x (Jm + Jb)

tb =
0.45 x (Mmax + Mstart) Countercurrent braking Starting Speed

where tb = Braking time, s

K1 = Constant depending on number of poles, see Figure 2
table
Jm = Moment of inertia of motor, kgm2 (It is a complicated matter to calculate theoretically the braking
Jb = Moment of inertia of load, referred to speed of torque curve for countercurrent braking. In most cases it can be
assumed that the braking torque is approximately equal to the
motor, kgm2
acceleration torque, when the load current is approximately
Mmax = Maximum torque of motor, Nm
zero.)
Mstart = Starting torque of motor, Nm

Frequency Constant K1 for different number of poles

Hz 2 4 6 8 10
With countercurrent braking there is no braking action in the
50 345 157 104 78 62 event of power failure. The technique is therefore unsuitable for
60 415 188 125 94 75 use in plant where loss of braking could cause danger.

Although the load torque contributes to the braking torque, Speed detector with countercurrent braking
making allowance for it complicates the calculation unduly if the
braking time must be accurately known. It can therefore be said
A low speed detector designed to cut off the supply to the motor
that the braking torque is approximately equal to the
when the speed approaches zero can be used to terminate
acceleration torque, when the load current is approximately
countercurrent braking at the right instant. The speed detector
zero.
is usually mounted on the N-end of the motor and is driven from
the motor shaft via a coupling.

18
Direct-current braking Regenerative braking

When braking with this technique, the a.c. supply to the motor is
disconnected and the stator is excited with direct current; this
causes the motor to produce a braking torque.
An ordinary standard motor and suitable equipment for d.c.
excitation may be used. The a.c. voltage follows a decay curve,
and the d.c. voltage must not be connected until the a.c. voltage
has fallen to a value at which it will not harm the d.c. equipment.
The excitation current is determined by the braking time
chosen, but is usually 1 to 2 times the rated current of the
motor. However, saturation of the magnetic circuit imposes a
limit on the braking torque.
Direct-current braking gives a far longer braking time than
countercurrent braking, however high the excitation current, but
thermal losses are lower, so more frequent braking is
permissible.
If the d.c. voltage fails there will be no braking action. The
technique is therefore unsuitable for use in plants where loss of
braking could cause danger.
This is the method of braking multi-speed motors when
changing down to lower speeds. The thermal stresses are
approximately equal to those occuring when motors with dual
speed connections are started at lower rated speed. With the
motor at the lower speed working as a generator, it develops
very high braking torque in the interval between operating
speeds of motor corresponding to the two poles. The maximum
braking torque is slightly higher than the starting torque of the
motor at the lower speed. Regenerative braking is also used
with variable speed drives.
Based on the thermal stesses developed during different
braking methods, with reference to those developed during
direct-on-line starting, following thermal equivalence is drawn.
Four jogs (or inching) = One start
One DC injection braking = Two start
One plug stop = Three start
One regenerative braking = One start

Time
Figure 3
(The lower curve shows the output voltage from the stator
winding of a small induction motor after disconnection from the
supply. Only half the curve is shown. The upper curve is a 50
Hz scale. With countercurrent braking, the d.c. voltage must not
be connected until the a.c. voltage has fallen to a value at which
it will not harm the d.c. equipment.)

Torque
Torque

Braking torque
Acceleration torque Mb

Torque

Direct-current braking Starting

Figure 4

(Example of braking torque with d.c. braking and different

excitation currents.
In = rated current of motor.)

19
Duty types

The duty types are indicated by the symbols S1 ... S9 according to IS:12824-1989. The outputs given in the tables are based on
continuous running duty. S1 with rated output.

S1 P
Continuous running duty
N
Operation at constant load of sufficient duration for thermal
equilibrium to be reached. In the absence of any indication of
the rated duty type, continuous running duty will be assumed.

Designation: S1

Time

S2 P
Short-time duty N

Operation at constant load during a given time, less than

required to reach thermal equilibrium, followed by a rest and de-
energised period of sufficient duration to re-establish motor
temperatures equal to the ambient or the coolant temperature.
The values 10, 30, 60 and 90 minutes are recommended for the
rated duration of the duty cycle.

Designation e.g. S2 60 min.

Time

S3 P
Intermittent duty N R

A sequence of identical cycles, each including a period of

operation at constant load and a rest and de-energised period.
The period is too short for thermal equilibrium to be obtained.
The starting current does not significantly affect the temperature
rise.

Recommended values for the cyclic duration factor are 15, 25,
40 and 60%. The duration of the duty cycle is 10 min.

Designation e.g. S3 25% Time

Period of one cycle

S4
Intermittent duty with starting P

A sequence of identical duty cycles, each cycle including a Period of one cycle
significant period of starting, a period of operation at constant
load and rest and de-energised period. The period is too short
for thermal equilibrium to be obtained. In this duty type the
motor is brought to rest by the load or by mechanical braking,
where the motor is not thermally loaded. After the duty type the
following factors must be indicated; the cyclic duration factor;
the number of duty cycles per hour (c/h); the factor of inertia FI;
Time
the moment of inertia, JM, of the motor rotor; and the permissible D N R
average moment of resistance, TV, during the change of the
speed given with the rated load torque. The factor inertia FI is
the ratio of the total moment of inertia, to the moment of inertia P = Output power V = Operation of no load
of the motor rotor. D = Starting R = At rest and de-energised
N = Operation under rated condition
Designation e.g. S4 - 25% - 129 c/h - FI.2 - JM = 0,1 kgm2 - TV = F = Electrical braking
0,5 TV.

20
S5
Intermittent duty with starting and electrical P
braking
Period of one cycle
A sequence of identical duty cycles, each cycle consisting of a
significant period of starting, a period of operation at constant
load, a period of rapid electric braking and a rest and de-
energised period. The period is too short for thermal equilibrium
to be obtained.

After the duty type the following factors must be indicated: the D Time
cyclic duration factor; the number of duty types per hour (c/h); the
factor of inertia FI; the moment of inertia JM, of the motor, and the F
permissible moment of resistance TV (see duty type S4.)
N R
Designation e.g. S5-40% -120 c/h- FI.3 - JM = 1,3 kgm2 - TV = 0,3 TN.
Period of one cycle
S6
Continuous-operation periodic duty
P
A sequence of identical duty cycles, each cycle consisting of a
period at constant load and period of operation at no load. The N
period is too short for thermal equilibrium to be obtained. V

Recommended values for the cyclic duration factor are 15, 25, 40
and 60%. The duration of the duty cycles is 10 min.
Time
Designation e.g. S6 40% P = Output power V = Operation of no load
D = Starting R = At rest and de-energised
N = Operation under rated condition
F = Electrical braking

S7 S8
Continuous-operation periodic duty with Continuous-operation periodic duty with related
electrical braking load speed changes
A sequence of identical duty cycles, each cycle consisting of a
period of starting, a period of operation at constant load and a
period of braking. Braking method is electrical braking e.g.
countercurrent braking. The period is too short for thermal
equilibrium to be obtained.
After the duty type the following factors must be indicated: the
number of duty cycles per hour c/h, the factor of inertia FI: the
moment of inertia JM of the motor, and the permissible moment of
resistance TV ( See duty type S4)
Designation e.g. S7 40% - 500 c/h - FI.2 - JM = 0.08 kgm2 - TV =
0,5 TN.
A sequence of identical duty cycles, each cycle consisting of a
period of starting, a period of operation at constant load
corresponding to a predetermined speed of rotation, followed by
one of more periods of operation at other constant loads
corresponding to different speeds of rotation. The period is too
short for thermal equilibrium to be obtained. This duty type is
used for example by pole changing motors.
After the duty type the following factors must be indicated; the
number of duty cycles per hour c/h; the factor of inertia FI; the
permissible average moment of resistance TV (see duty type S4);
the cyclic duration factor for each speed of rotation and the
moment of inertia JM of the motor.
Designation e.g.

S8 - 30 c/h - FI.30 - TV = 24 kW - 740 rpm - 30%

S9
Duty with non-periodic load and speed variations
A duty in which, generally, load and speed are varying non-
periodically within the permissible operating range. This duty
includes frequently applied overloads that may greatly exceed the
full loads. For this duty type, suitable full load values should be
taken as the basis of the overload concept.
30 c/h - FI.30 - TV = 0.5 TN = 60 kW - 1460 rpm - 30%
30 c/h - FI.30 - TV = 0.5 TN = 45 kW - 980 rpm - 40%
JM = 2,2 kgm2
The combinations of the load and speed of rotation are designed
in the order they occur in use.

21
Protection accessories

Space heaters Thermistors

Motors subjected to atmospheric condensation, either through
standing idle on a damp environment or because of the wide
variation in the temperature of the surroundings, may be fitted
with a heater for extra precaution. The heater ensures that the
temperature of the air inside the motor, is maintained a few
degrees above that of the ambient to avoid any condensation.
Such heaters shall not be kept ON when the motor is operating.
These space heaters are generally rated for 240 V ac/dc.
For motors not having the provision of space heaters, 24 V dc
supply can be applied between any two terminals.
The leads of space heaters for frame 160 to 400 are terminated
in a separate auxiliary terminal box
PTC thermistor is the most common type of temperature
detector. It is the characteristics of the thermistors that its
resistance hardly varies with increasing temperature until the
threshold temperature is reached, thereafter the resistance
increases sharply as shown in figure below. Thermistors must
be connected to a separate control unit which trips power circuit
when the resistance in the thermistor circuit increases abruptly.
Thermistors generally provided are rated for 130°C (PTC 130)
for class B rise and 155°C (PTC 155) for class F rise.
Normally three thermistors are provided in series - one
thermistor in each phase. Six nos. (three nos. for tripping and
three nos. for alarm.) can be provided if intimated at the time of
enquiry.

Guide for fuse protection Like space heaters, the leads of thermistors for frame 160 to
400 are terminated in a separate auxiliary terminal box.
In addition to the starters being used to protect motors from
overload and under voltage, the motors are protected with fuse
as per the following table

kW Full load Fuse rating, A Characteristic of a thermistor

current, A
ohms
DOL start Y/D start

0.37 1.2 6
0.55 1.6 6 4000
0.75 2.1 6
1.1 2.9 6
1.5 4.0 10 1330
2.2 5.7 16 10
3.7 8.3 16 16
4.0 9.5 25 16 550
5.5 12.2 25 16
7.5 15.5 25 25
9.3 19.4 32 25
11 22 32 25
15 29.5 50 50 100
18.5 37 63 50
22 42 63 63
30 52 80 63
37 66 100 80
45 80 125 100
55 98 160 125
75 128 200 160
90 155 225 200
110 188 250 200
132 223 315 250
160 270 355 300 Typical value _
200 332 400 350 Shaded area = tolerance limits
250 415 500 500

22
Voltage drop along the cable

Induction motors draw heavy currents during starting, resulting Determination of withstand capability
in considerable voltage drop along the cable, If other loads are
connected in parallel to the motors, the voltage drop along the Since the negative sequence currents result in overloading, the
common feeder causes operational problems to these amount of negative sequence current carried by the winding as
associated loads. Larger the starting current and longer the a percentage of rated current can be used as a measure of
common feeder, larger will be the voltage drop. In view of this overloading due to unbalance. The thermal withstand
while specifying motors or cables, it is required to estimate the characteristics of the machine available for different overload
right combination of starting current and cable size, alternatively, it conditions can be used to represent the capacity of the machine
is important to know voltage drop for an installation when to withstand negative sequence voltage and current. The
starting / locking of motors occurs such that the maximum negative sequence withstand characteristics are design specific
voltage drop is less than 3%. The relative voltage drop, D u is and will vary from motor to motor. A sample method for obtaining
estimated as negative sequence withstand characteristics of the motor is
Du = u- *100 given hereunder.
U
where, U is the rated voltage of the motor Sample calculation:
u is the voltage drop given as Let nominal voltage be 415 V and rated current be 60A.
Under unbalance condition let the voltages be
(
u = b rx L cosf + lLsinf Is
S
V = 385 L0° V
where u = Voltage drop V = 410 L120° V
b = Factor equal to 1 for three-phase circuits and V = 425 L 240° V
equal to 2 for single phase circuits
385 + 410 + 425
r = Resistivity of conductors in normal duty Average voltage = = 407V
taken as being equal to the resistivity at the 3
normal duty temperature, i.e. 1.25 times the Unbalance voltage = 425 - 407 x 100 = 4.42%
resistivity at 20°C, giving 0.02250 mm2/m for 407
copper and 0.0360mm2/m for aluminium Negative sequence voltage
L = Length of cabling in meters
385Ð0° + a2410Ð120° + a425Ð240°
S = Cross section of conductors in mm2 VN = =11.66Ð158° V
3
cosf = Power factor, if exact figure is not available it
is equal to 0.8 and sin~ = 0.6 % negative sequence voltage = 11.66 / 407 = 2.86% (appx. 3%)
l = Linear reactance of conductors, taken as
being equal to 0.08mQ/m if the exact figure Now if the parameters of the machine are as given below:
is not available R1 = 0.052
lS = Current in use R2 = 0.071
X1 = 0.51
X2 = 0.53
Negative sequence withstand characteristics s = 0.0123
then s1 = 2. 0.0123 = 1.9877
Negative sequence withstand characteristics are used to obtain
capability of the motor to withstand the overloading caused by From the equivalent circuit diagram
negative sequence currents that occur due to unbalance in VN
supply voltage. (R1+ R2 1s1)+ j(X1 + X2)

While % unbalance in voltage is given by the ratio 11.66L158°

(0.052 + 0.071/1.9877) + j (0.51+ 0.53)
Max. deviation (phase value) from average value x 100
Average value = 11.17 L -243.4°
This corresponds to 18.6% (approx. 20%) of the rated current
The negative sequence voltage, VN for any degree of unbalance
for the case considered here. This condition can be equated to
can be calculated by an overload of 20%. Now the thermal withstand characteristics
of the motor can be used to obtain the thermal withstand time
VN = 1/3 (Va + (a2Vb + a Vc) for this particular motor. Similarly, thermal withstand time for
where a = 1 L120° and a2 = 1 L240º different negative sequence voltage of voltage unbalance can
be calculated.
Estimation of negative sequence current
The following table gives the thermal withstand time of this
Once negative sequence voltage is known amount of negative sample motor for different negative sequence voltage.
sequence current that is ultimately responsible for overloading % negative % negative withstand time, sec
can be estimated from the following equivalent circuit of the sequence sequence
motor. The value of circuit parameters can be obtained from voltage current Cold Hot
design or from test results.
1 6 continuous continuous
2 10 continuous continuous
3 20 3500 1800
R1 X1 R2/S1 X2
6 40 1600 600
9 60 1100 400

23
Power factor improvement chart

Present Desired power factor, COSf2

power
factor
0.7 0.75 0.8 0.82 0.84 0.86 0.88 0.9 0.92 0.94 0.96
COSf1
0.30 2.16 2.30 2.42 2.48 2.53 2.59 2.65 2.70 2.76 2.82 2.89

0.35 1.66 1.80 1.93 1.98 2.03 2.08 2.14 2.19 2.25 2.31 2.38

0.40 1.27 1.41 1.54 1.60 1.65 1.70 1.76 1.81 1.87 1.93 2.00

0.45 0.97 1.11 1.24 1.29 1.34 1.40 1.45 1.50 1.56 1.62 1.69

0.50 0.71 0.85 0.98 1.04 1.09 1.14 1.20 1.25 1.31 1.37 1.44

0.52 0.62 0.76 0.89 0.95 1.00 1.05 1.11 1.16 1.22 1.28 1.35

0.54 0.54 0.68 0.81 0.86 0.92 0.97 1.02 1.08 1.14 1.20 1.27

0.56 0.46 0.60 0.73 0.78 0.84 0.89 0.94 1.00 1.05 1.12 1.19

0.58 0.39 0.52 0.66 0.71 0.76 0.81 0.87 0.92 0.98 1.04 1.11

0.60 0.31 0.45 0.58 0.64 0.69 0.74 0.80 0.85 0.91 0.97 1.04

0.62 0.25 0.39 0.52 0.57 0.62 0.67 0.73 0.78 0.84 0.90 0.97

0.64 0.18 0.32 0.45 0.51 0.56 0.61 0.67 0.72 0.78 0.84 0.91

0.66 0.12 0.26 0.39 0.45 0.49 0.55 0.60 0.66 0.71 0.78 0.85

0.68 0.06 0.20 0.33 0.38 0.43 0.49 0.54 0.60 0.65 0.72 0.79

0.70 0.14 0.27 0.33 0.38 0.43 0.49 0.54 0.60 0.66 0.73

0.72 0.08 0.22 0.27 0.32 0.37 0.43 0.48 0.54 0.60 0.67

0.74 0.03 0.16 0.21 0.26 0.32 0.37 0.43 0.48 0.55 0.62

0.76 0.11 0.16 0.21 0.26 0.32 0.37 0.43 0.50 0.56

0.78 0.05 0.11 0.16 0.21 0.27 0.32 0.38 0.44 0.51

0.80 0.05 0.10 0.16 0.21 0.27 0.33 0.39 0.46

0.82 0.05 0.10 0.16 0.22 0.27 0.33 0.40

0.84 0.05 0.11 0.16 0.22 0.28 0.35

0.86 0.06 0.11 0.17 0.23 0.30

0.88 0.06 0.11 0.17 0.25

0.90 0.06 0.12 0.19

0.92 0.06 0.13

0.94 0.07

The power factor compensating capacitors are specified in terms of kVAR. The input kW of the motor is multiplied by the reading
to obtain the necessary improvement in the power factor.
Example - If the initial power factor = COSf1 =0.76
Input active power = 100 kW
Corrected power factor = COSf2 =0.90
From the chart: capacitor kVAR required per kW load = 0.37
hence
Total capacitor kVAR required = 0.37 x 100 = 37 kVAR

24
Mechanical

Enclosure Terminal box

Motors in frame 71 to 315 have cast iron enclosures and larger
ones have fabricated enclosures. Foot mounted motors have
integrated feet. The housing and the end shields are machined
to class tolerances to obtain perfect alignment and fits.
Core
The stator and rotor cores of the motor are made of high quality
cold rolled non-grain oriented magnetic steel having low iron
loss.
Protection against corrosion
As standard practice, the terminal box is located on the top of
the motor. Extended side terminal box can be offered for frame
90 to 280. The terminal boxes for frames 71 to 280 are
rotatable in the steps of 900 and are made of die cast aluminum
alloy. For frames 225 and 400 the terminal boxes are rotatable
in steps of 900 and are made from cast iron. For all the terminal
boxes protection of enclosure of IP 55.
Motor upto 1.5 kW (2 hp) are provided with 3 terminal and
others are provided with 6 terminals as standard practice. The
terminal plates and lead ferrules are marked U1, V1 and W1, of
U1, V1, W1 and U2, V2, W2. Terminal boxes have provision for
fixing cable glands to support copper or aluminum cables.

Special attention has been paid to the finish. Polyurethane paint
is applied to motors. This provides an excellent finish and
protection against corrosion. The color of the paint is Munsell
Blue.
All the hardware are zinc passivated to give reliable anti-
corrosion protection under most server environmental
conditions.
Winding and insulation
The insulation of the motors meet class F requirements
(temperature limit 155°C) the normal temperature however
does not exceed the values permitted by class B (temperature
limit 130°C). The motors therefore have large overload margin
and long winding lifetime. If the temperature rise to class F is
allowed, the outputs given in the table can generally be
increased by approximately 12%.
Drain holes
Motors for operation in very humid or wet environments, and
especially under intermittent duty, should be provided with drain
holes.
HX Motors from frame HX 180 onwards are provided with drain
holes and closeable plastic drain plugs in the drain holes. The
plugs will be opened, on delivery. When mounting the motors, it
should be ensured that the drain holes face downwards. In the
case of vertical mountings, the upper plug must be hammered
home completely. In very dusty environments, both plugs
should be hammered home.

Motor stators are wound with enamel wire and the winding is
then impregnated with solventless resin. The impregnation
effectively fills the gaps between conductors and makes the
winding mechanically strong, moisture and tropic proof.

The rotor cages of the motors upto 315 frames have die cast
construction whereas those of larger motors have fabricated
construction.

Earthing
Provision is given for earthing of motor. One earthing terminal
on terminal box and two earthing terminals on motor body are Open
provided.

Shaft and shaft extension

Closed

The shaft is made of EN8/C40 steel. On special request shaft

with EN24 steel can be offered. Standard motors have
cylindrical shaft extension in accordance with IS:1231.

Non standard shaft extensions on drive end are also available

on request. Orders should be accompanied by a sketch of the
shaft extension and if need be, a clear text description. A
second shaft extension has to be ordered as a special design.

All shaft extension of frame sizes have a drilled and tapped

shaft according to IS:1231. All standard flange motors comply
with tolerances N (normal) according to IS:2223 with respect to
shaft extension runout, concentricity and perpendicularity of the
extension in relation to the flange face.

25
Exploded view of HX motors

19

18

17

16

15

13
11

10 14

12

6
CD
A
M
RV

3 23

1 21

22

20

1 Bearing Cover DS Outer 13 Bearing NDS

2 Endshield DS 14 Bearing Cover NDS Inner
3 Bearing DS 15 Endshield NDS.
4 Bearing cover DS inner 16 Bearing Cover NDS Outer
5 Shaft extension key 17 Fan
6 Rotor assembly 18 Circlip
7 Fan key 19 Fan Cowling
8 Wound stator 20 Grease Outlet Plug
9 Terminal box 21 Regreasing Hole
10 Terminal plate 22 Drain Hole Plug
11 Terminal box cover 23 Earthing Bolt
12 Eye bolt
26
Pulley diameter

When the desired bearing life has been determined, the minimum Permissible radial forces
permissible pulley diameter can be calculated using FR' as follows: Motor sizes 71 to 132
7
D= 1.9 x 10 x K x P
n x FR
Length of Ball bearings
where: shaft
D = Diameter of pulley, mm Motor extension 20,000 hours
P = Power requirement, kW size Poles E (mm) X0(N) Xmax(N)
n = Motor speed, r/min
K = Belt tension factor, dependent on belt type 71 2 30 415 335
and type of duty. A common value for 4 30 415 335
V-belts is 2.5. 6 30 415 340
FR= Permissible radial force
80 M 2 40 670 545
4 40 890 725
Permissible loadings on shaft 6 40 970 830

The tables below give the permissible radial force in newtons, 90 SL 2 50 795 625
assuming zero axial force. The values are based on normal 4 50 995 780
conditions at 50Hz and calculated bearing lives for motor sizes 71 6 50 1135 880
to 132 of 20000 hours and for motor sizes 160 to 400 of 20,000 and
40,000 hours. 100 2 60 1090 875
4 60 1360 1095
Motors are foot-mounted 1MB3 version with force directed 6 60 1560 1250
sideways. In some cases the strength of the shaft affects the
permissible forces. 112 2 60 1410 1120
4 60 1735 1400
At 60Hz the values must be reduced by 10%. For two - speed 6 60 2000 1620
motors, the values must be based on the higher speed.
132 SM 2 80 1700 1330
Permissible loads of simultaneous radial and axial forces will be 4 80 2130 1660
supplied on request. 6 80 2495 1935

If the radial force is applied between points X0 and Xmax' the

permissible force FR can be calculated from the following formula :

FR=FX0 - (FX0 - FXmax)

E = length of shaft extension in basic version

FR
X

Xmax X0

27
Permissible radial forces

Motor sizes 160 to 400

Length of Ball bearings Roller bearings

shaft
Motor extension 20,000 hours 40,000 hours 20,000 hours 40,000 hours
size Poles E (mm) X0(N) Xmax(N) X0(N) Xmax(N) X0(N) Xmax(N) X0(N) Xmax(N)

160 2 110 2980 2310 2350 1810 5530 4260 4370 3360
4 110 3760 2900 2970 2290 6980 5380 5520 4250
6 110 4290 3300 3390 2750 7980 6150 6310 4860
8 110 4730 3660 3740 2880 8800 6780 6960 5360

180 2 110 3540 2880 2790 2260 6260 5080 4940 4010
4 110 4390 3560 3440 2790 7830 6350 6160 5000
6 110 5060 4110 3970 3220 9000 7300 7100 5750
8 110 5590 4540 4390 3560 9940 8060 7830 6350

200 ML 2 110 4510 3700 3530 2900 8520 7000 6710 5510
4 110 5660 4650 4430 3640 10710 8800 8440 6930
6 110 6470 5310 5050 4150 12250 10060 9640 7920
8 110 7160 5880 5600 5880 13520 11100 10650 8750

225 SM 2 110 4750 4010 3710 3130 9720 8200 7650 6450
4 140 6310 5040 4920 3840 12900 10310 10150 8120
6 140 7200 5760 5620 4500 14740 11800 11600 9280
8 140 7970 6375 6230 4980 16270 13010 12820 10250

250 SM 2 140 6100 4910 4750 3830 13600 10960 10710 8640
4 140 7650 6170 5960 5450 17100 13800 13470 10870
6 140 8700 7010 6760 5450 19520 15740 15360 12400
8 140 9630 7760 7505 6050 21550 17380 16970 13690

280 SM 2 140 7300 6200 5800 4900 20200 6600 16500 6600
4 140 9200 7800 7300 6200 25000 12000 20300 12000
6 140 10600 8900 8400 7100 28000 12000 23000 12000
8 140 11600 9800 9200 7800 30700 12000 25000 12000

315 SML 2 140 7300 6000 5800 4950 20200 6350 16500 6350
4 170 11300 9400 9000 7500 32500 10700 26500 10700
6 170 13000 10600 10300 8500 37000 10600 30000 10600
8 170 14300 10400 11300 9400 40000 10400 32700 10400

355 SM 2 140 9000 7900 6100 5300 26700 8900 21800 8900
4 210 15200 12500 12000 9850 45000 21400 36700 21300
6 210 17300 14300 13700 11300 51000 21100 41500 21100
8 210 19000 15700 15200 12400 55500 21700 45200 21700

355 ML 2 140 9100 7100 6100 5400 26900 7100 21800 7100
4 210 15200 12800 12000 10100 45500 19500 36700 19500
6 210 17300 14600 13700 11500 51000 19000 41500 19000
8 210 19300 16200 15200 12700 55500 19500 45200 19500

400 L 2 140 8900 3000 5700 3000 27000 3000 22000 3000
4 210 15000 13000 11700 10100 46000 15000 37000 15000
6 210 17200 13700 13600 11700 52000 13700 42000 13700
8 210 19200 15000 15000 12900 55500 15000 46000 15000

28
Permissible axial forces

The following tables give the permissible axial forces in newton,
assuming zero radial force. The values are based on normal
conditions at 50Hz with standard bearings and calculated
bearing lives of 20,000 and 40,000 hours.
At 60 Hz the values are to be reduced by 10%.
For two-speed motors, the values are to be based on the higher
speed. The permissible loads of simultaneous radial and axial
forces will be supplied on request.
Given axial forces FAD' assumes D-bearing locked by means of
locking ring.

FAD FAZ
Mounting arrangement 1M83

20,000 hours 40,000 hours

2-pole 4-pole 6-pole 8-pole 2-pole 4-pole 6-pole 8-pole

Motor FAD FAZ FAD FAZ FAD FAZ FAD FAZ FAD FAZ FAD FAZ FAD FAZ FAD FAZ
size N N N N N N N N N N N N N N N N

71 270 270 350 350 440 440 - - 1) 1) 1) 1) 1) 1) - -

80 400 400 510 510 590 590 - - 1) 1) 1) 1) 1) 1) - -
90 450 450 560 560 640 640 - - 1) 1) 1) 1) 1) 1) - -
100 620 620 780 780 890 890 - - 1) 1) 1) 1) 1) 1) - -
112 810 810 1020 1020 1170 1170 - - 1) 1) 1) 1) 1) 1) - -
132 980 980 1220 1220 1400 1400 - - 1) 1) 1) I) I) 1) - -
160 2120 2120 2660 2660 3040 3040 3360 3360 1670 1670 2100 2100 2400 2400 2640 2640
180 2480 2480 3070 3070 3540 3540 3910 3910 1950 1950 2430 2430 2780 2780 3070 3070
200 3050 3050 3850 3850 4400 4400 4850 4850 2430 2430 3050 3050 3500 3500 3850 3850
225 3440 3440 4340 4340 4960 4960 5460 5460 2730 2730 3440 3440 3940 3940 4340 4340
250 4180 4180 5260 5260 6020 6020 6630 6630 3320 3320 4180 4180 4780 4780 5260 5260
280 7300 5300 8000 6000 9000 7000 10000 8000 5750 3750 6200 4200 6900 4900 7700 5700
315 7000 5000 9000 7000 10600 8600 11600 9600 5600 3600 6900 4900 7900 5900 8900 6900
355 10500 3500 13500 6500 15300 8300 16800 9800 8750 1750 10800 3800 12000 5000 13300 6300
400L 10100 32001 3000 6000 15000 8000 16500 9500 8350 1350 10200 3250 11800 4800 13000 6000

FAZ

Mounting arrangement 1MV1 FAD

20,000 hours 40,000 hours

2-pole 4-pole 6-pole 8-pole 2-pole 4-pole 6-pole 8-pole
Motor FAD FAZ FAD FAZ FAD FAZ FAD FAZ FAD FAZ FAD FAZ FAD FAZ FAD FAZ
size N N N N N N N N N N N N N N N N

71 290 260 380 330 460 420 - - 1) 1) 1) 1) 1) 1) - -

80 430 390 540 490 620 560 - - 1) 1) 1) 1) 1) 1) - -
90 480 420 610 520 700 600 - - 1) 1) 1) 1) 1) 1) - -
100 680 580 880 740 990 840 - - 1) 1) 1) 1) 1) 1) - -
112 890 760 1140 950 1280 1100 - - 1) 1) 1) 1) 1) 1) - -
132 1100 919 1390 1120 1580 1300 - - 1) 1) 1) 1) 1) 1) - -

160 2420 1820 3040 2280 3480 2600 3810 2920 1970 1370 2480 1720 2840 1960 3090 2200
180 2860 2100 3690 2450 4160 2920 4530 3290 2300 1570 3050 1810 3400 2160 3690 2450
200 3600 2500 4580 3120 5280 3530 5720 3980 2970 1870 3780 2320 4370 2620 4720 2980
225 4140 2740 5230 3440 6030 3900 6530 4400 3430 2030 4330 2550 5010 2870 5400 3270
250 5020 3330 6380 4150 7440 4610 8050 5210 4160 2470 5290 3060 6200 3360 6680 3840
280 8500 4300 9500 4600 11000 5500 12200 6600 6950 2700 7700 2800 8900 3350 9750 4200
315 SML 9000 3700 11600 5400 13500 6200 14500 7500 7450 2100 9450 3200 10900 3650 11900 4650
355 SM 14900 800 19200 3100 22200 4100 24000 5800 13000 1) 16400 1) 18900 850 20300 2100
355 ML 15000 1) 19800 1700 23100 2500 25000 4300 13100 1) 17000 1) 19800 1) 21300 1)
400 L 17300 1) 21800 1) 24300 1000 26200 2500 15400 1) 18900 1) 21100 1) 22500 1)

1) On request

29
Testing

The standard test programmes are dividing into four parts: Type test
routine tests, type tests, optional tests and special tests. The
routine test program is done to every machine. Type test is 1. Dimensions
performed in addition to routine tests normally to one of the 2. Measurement of resistance of stator
machines of a series of similar machines or by a request of the
3. Locked rotor test
customer. Optional tests are additional type tests subject to
mutual agreement between purchases and the manufacturer. 4. Temperature rise test
Special tests are needed if the machine has to run in special 5. Full load test
conditions e.g. roller table, hazardous areas, cranes 6. No load test at rated voltage
applications. The special test program is specified by the 7. Reduced voltage running test
customer/consultant/standards bureaus. 8. Momentary overload test
9. Insulation resistance test
If the motor will be fed by a frequency converter it is most often 10. High voltage test
tested together with the frequency converter.
Optional tests
Unless otherwise specified all the tests are performed
according to standard IS:325-1996.
1. Vibration severity test
2. Sound level measurement
Contents of test programmes: 3. Degree of protection test
4. Temperature rise test at limiting values of voltage and
Routine tests frequency variation
5. Over speed test
1. Insulation resistance test 6. Test on insulation system
2. Measurement of resistance of the stator
3. Locked rotor test Special tests
4. No load test
5. Reduced voltage running test 1. Acceleration constant test (B value test, for roller table
6. High voltage test motors)
2. tE time test (for increased safety motors)
3. Suitability to PWM supply

30
Motors for frequency converter drive

Squirrel cage induction motors offer excellent availability,
reliability and efficiency. In addition to that, a motor with a
frequency converter - variable speed drive (VSD) - has even more
excellent properties. A variable speed drive motor can be started
softly with low starting current, and the speed can be controlled
and adjusted to suit the application demand without steps over a
wide range. Also the use of a frequency converter together with a
squirrel cage motor usually leads to remarkable energy savings.
At low speed operation the motor's ventilation fan loses its cooling
capacity, which causes a higher temperature rise in the motor
and bearings. A separate constant speed fan can be used to
increase cooling capacity and loadability at low speed. It also
important to check the performance of the grease at low speeds.
3. Lubrication

Most of the squirrel cage motors manufactured by ABB are
suitable for variable speed use, but in addition to the general
selection criteria, the following points must be taken into account:
1. Dimensioning
The voltage (or current) fed by the frequency converter is not
purely sinusoidal. This may increase the losses, vibration, and
noise of the motor. Furthermore, a change in the distribution of the
losses may affect the motor temperature balance and lead to an
increase in the temperature of the bearings. In every case, the
motor must be correctly sized according to the instructions
supplied with the selected frequency converter.
When using ABB converters use the Drive Size dimensioning
program or "ISOTHERM GUIDE-LINES" of the corresponding
converter type for sizing the motors. The loadability curve of a
standard motor used with a ACS 600-frequency converter can be
found from figure 3.
The effectiveness of the motor lubrication should be checked by
measuring the bearing temperature under normal operating
conditions. If the measured temperature is higher than + 80°C, the
relubrication intervals specified in ABB' s standard instruction
manuals must be shortened; i.e. the relubrication interval should
be halved for every 15K increase in bearing temperature. If this is
not possible ABB recommends the use of lubricants suitable for
high operating temperature conditions. These lubricants allow
normal relubrication interval and a 15K increase in bearing
temperature conditions.
4. Insulation protection
If the frequency converter has IGBT power components with very
rapid switching, practically all cables between the converter and
the motor will be long. In that case, steep voltage pulses and
reflections at the cables increase voltage stresses at the winding
of the motor and therefore, the precautions described in figure 2
below must betaken to avoid risks of insulation damage.

For GTO converters, consideration must be given to the

2. Speed range
In a frequency converter drive, the actual operating speed of the
motor may deviate considerably from its nominal speed (i.e. the
speed stamped on the rating plate).
information about cable length, pulse rise time and the voltage
overshoot using the voltage/ cable length guideline.
5. Bearing currents

For higher speeds, ensure that the highest permissible rotational Bearing voltages and currents must be avoided in all motors.
speed of the motor or the critical speed of the entire equipment is When using an IGBT frequency converter insulated bearings
not exceeded. When high speed operation exceeds the nominal and/or a properly dimensioned filter at the converter output must
speed of the motor, the following points should be checked: be used according to instructions in figure 2 below. (For other
alternatives and converter types, please contact ABB.) When
• Maximum torque of the motor ordering clearly state which alternative will be used.
• Bearing construction
• Lubrication For more information about bearing currents and voltages, please
• Balancing contact ABB.
• Critical speeds
• Shaft seals 6. Cabling, grounding and EMC
• Ventilation
• Fan noise The use of a frequency converter causes some extra
requirements on the cabling and grounding of the drive system.
Permissible maximum speeds for standard motors are described The motor must be cabled by using shielded symmetrical cables
in figure 1. and cable glands providing a 360º bonding (also called EMC-
glands). For motors up to 30 kW unsymmetrical cables can be
Figure 1. used, but shielded cables are always recommended.
Maximum permissible speeds for basic motors
For motor frame size 280 and upward, additional potential
Frame size Speed r/min equalisation between the motor frame and the machinery is
2-pole 4 -pole needed, unless they are installed on a common steel fundament.
When a steel fundament is used for the potential equalisation, the
71 - 200 4000 3600 high frequency conductivity of this connection should be checked.
225 - 280 3600 2600
315 3600 2300 More information about grounding and cabling of a variable speed
355 3600 2200 drive can be found from the manual "Grounding and cabling of the
400 3600 1800 drive system" (Code: 3AFY 61201998RO125REVA)

31
For fulfilling the EMC requirements, special EMC cable(s) must be used in addition to the correct cable gland mounting, with special,
extra earthing pieces. Please refer to the manuals of the frequency converter.

Figure 2. Selection rule for insulation and filtering in variable speed drives

Motor nominal power PN or frame size

PN < 100 kW PN < 100 kW or 3IEC 315 PN < 350kW
U < 500 V Standard motor Standard motor Standard motor
N + Insulated N-bearing + Insulated N-bearing
+ Common mode filter
U < 600 V Standard motor Standard motor Standard motor
N + dU/dt-filter + dU/dt-filter + Insulated N-bearing
OR OR + dU/dt-filter
Reinforced insulation Reinforced insulation OR
+ Insulated N-bearing Reinforced insulation
+ Insulated N-bearing
+ Common mode filter
U < 690 V Reinforced insulation Reinforced insulation Reinforced insulation
N + dU/dt-filter + dU/dt-filter + Insulated N-bearing
+ dU/dt-filter
+ Light Common mode filter

dU/dt filter Motor loadability with ACS 600

Series reactor. dU/dt filters decrease the changing rate of the
phase and main voltages and thus reduce voltage stresses in
the windings. dU/dt filters also decrease so called common
mode currents and bearing currents.
Common mode and light common mode filters
Common mode filters are made of toroidal cores installed
around motor cables. These filters reduce so called common
mode currents in VSD applications and thus decrease the risk
of bearing currents. Common mode filters do not significantly
affect the phase or main voltages on the motor terminals. For
the exact type of the core, please contact ABB.
The loadability curve in figure 3 below is a guide line curve, for exact
values please contact ABB.
These guidelines present the maximum continuous load torque of a
motor as a function of frequency (speed) to give the same temperature
rise as with rated sinusoidal supply at nominal frequency and full rated
load.
The temperature rise of squirrel cage motors manufactured by ABB is
normally class B. If the ABB catalogue indicates that class F
temperature rise is utilised on a sinusoidal supply, the dimensioning of
the motor at frequency converter supply should be done according to
the temperature rise class B loadability curve

Common Mode Filter = 3 toroidal cores per each 3-phase motor For further information, please contact ABB. .
cable
Light Common Mode Filter = 1 toroidal core per each 3-phase
motor cable

Figure 3. Motor loadability with ACS 600, Field weakening point 50Hz.

32
Guide and check points for motor selection
(mechanical aspects)

1000m or less Altitude

Above 1000m Environment Corrosion
45°/50°C or less Ambient Dust, carbon, Etc
Low Temperature Humidity

Housing Protection Drip proof, IP23

Totally enclosed, IP55
Special, IP56

Totally enclosed
fan cooled Ventilation
Separately cooled
Natural cooled

Standard
Double shaft Shaft end Power Transmission Direct
Tapered Belt
Special Gear box

Mounting Foot
Horizontal Installation Flange
Vertical Face

Dimension IS/IEC
User specific

Epoxy Terminal Plate Terminal Box Position TOP/LHS/RHS

Bakelite Material Cast iron
Aluminum

Single armour Type

Double armour Cable Entry Bottom
Without armour Top
One or two Numbers side
size

Noise Standard
Low

Standard Vibration

Precision

Bearings Ball
Roller

Special paint shade Thermistor

Special name plate Others Space heater
Direction of rotation Brake
Tacho

33
Guide and check points for motor selection
(electrical aspects)

Drive torque Characteristics Torque

Operating speed of the load characteristics
Transfer efficiency
Load GD2 Operating Continuous operation
Load torque characteristics Intermittent duty & CDF

Equivalent starts
per hour

Rated output Single speed

and speed Dual speed
VVVF application

Single voltage with variations voltage

110V - 660V
Dual voltage - l / D
D / DD

Frequency 50 Hz

Any other frequency

Type of starting DOL start

Star-Delta start
Auto-transformer start % tapping
Soft start

Mechanical Braking
Plugging
DC injection
Regenerative

Torque
Characteristics Normal starting
High torque
Soft starting (Low pull out torque)

B/F Temperature
F/F rise / insulation
F/H

Determination
of motor
specification

34
Ordering Information

Customer Name_____________________________________ 18 Starting current

Date______________________________________________ • 600% subject to IS tolerance
Application_________________________________________ • 600%maximum
01 Output_______________kW (___________________hp) • Other_________________% full load current
02 Frame size____________________________________ 19 Starting method
03 Volatge______________________________________V • Direct-on-line (full voltage)
04 Voltage variation_______________________________%
• Star-Delta
05 Frequency Hz • 50 • 60, Other___________________Hz
• Auto-Transfer___________%taping____________secs
06 Frequency variation____________________________%
07 Number of poles • Frequency converter

08 Ambient temperature • Frequency range____________Hz to____________Hz

• 45°C • Fieldweakning point____________________________
• 50°C • Load torque speed curve________________________
• Special (Specify)_____________________________0C 20 Braking details
09 Temperature rise by resistance method
• No braking
• 70°C
• Electromechanical braking
• 75°C
• Countercurrent(Plugging)_________________no./hour
• 100°C
• Special (Specify)_____________________________0C • D.C. injection___________________________no./hour
10 Altitude • Reversal by plugging_____________________no./hour
• Standard (Sea level upto 1,000m) • Other (specify)________________________________
• Special (Specify) 21 Winding connection
11 Insulation • B • F • H
• Star • Delta • Special________________________
12 Duty • Continuous (S1)
22 Starting duty
• Other(Specify)______________________
• 1 Hot, 2 Cold, 3 Equally spread
13 Environment
• High humidity • Dusty • Tropical • Special (Specify)
• Corrosive gas, vapour 23 Load inertia with respect to motor shaft
• Area classification class • Actual GD2___________kgm2 at ___________rev./min
• Temp. Class______________• Division__________ 24 Load torque curve
14 Enclosure
• Enclosed
• Open drip proof (IP23)
• Not enclosed
• TEFC(IP44)
25 Method of coupling
• TEFC(IP55)
• Type 'n' (Non sparking) • Flexible • Belt • Gear box
• Type 'e' (Increased safety) • Fluid • Other ____________________________
• Type 'd' (Flame proof) 26 Belting data
• Special (Specify) • Motor pulley dia. and wt.____________mm________kg
15 Construction
• Load pulley dia. and wt._____________mm________kg
• Horizontal • Vertical • Special
• Centre distance between pulleys_______________mm
16 Mounting
• Type of belt___________________________________
• B3 • V1 • Other(Specify)
17 Applicable codes and standards • No. of belts___________________________________
• IS 325 27 Direction of rotation
• IS 6381 (Increased safety motors) • Bi-directional
• IS 9628 (Non sparking motors) • Clockwise from driving end
• IS 3682 (Flame proof motors)
• Anti-clockwise from driving end
• IPSS:1-03-007-85 (A.C. roller table motors)
• IS 2972 (Textile application)
• IS7538 (Agriculture application)
• Other_______________________________________
35
28 Terminal Box 35 Mounting base
• Without • Not required
• With • Slide rails
Location • Special(specify)_______________________________
• Top on driving end 36 Thrust for vertical motor
• Right side from driving end • Design thrust • Up__________kg • Down _______kg
• Left side from driving end • Momentary thrust
• Special (specify)______________________ • Up__________kg • Down _______kg
29 Terminal box construction 37 Rotor end float
• Stud type 3 terminals • ABB standard as per IS
• Stud type 6 terminals • Special(specify)____________________________mm
• Other_______________________________________ 38 Test
• External power cable • ABB standard (Non-witnessed)
Type________________________________________ Routine test as per IS 325
No. of cable____________No. of core______________ • Witness routine test as per IS 325
2
Conductor sectional area_____________________mm • Witness type test as per IS 325
Diameter : Overall ___________________________mm • Special (specify)_______________________________
Inner sheath_______________________mm 39 Any special requirement __________________________
Conduit size____________________________________ _____________________________________________
•Special (specify)_______________________________ _____________________________________________
30 Anti-condensation heater _____________________________________________
• Not required _____________________________________________
•________________Volt _____________________________________________
• Special (specify)_______________________________ _____________________________________________
31 PTC Thermistors
• Class B 130°C
• Class F 155°C
• Special (specify)_______________________________
32 Paint
• Standard Munsel Blue
• Epoxy shade 631 of IS 5
• Any other__________________________shade of IS 5
33 Balancing
• Half key (ABB standard)
• full key
33 Special features
• Export packing
• Tropical protection
• Foundation bolts
• Jacking facility
• Jacking bolts
• Grounding lug
• Cable gland
• Cable lugs Prepared by ___________
• Special (specify)_______________________________ Dated ___________

36
Frequency asked questions
Q. What are the general performance concerns of
motor?
Rated current, speed, starting current, starting torque, efficiency,
power factor, noise and vibration. Above all is the temperature rise
of the motor in accordance with operating environment and class
of insulation.
Q. Why is the consideration for efficiency growing ?
Higher efficiency means lower kW power drawn from electric
supply and hence, lower electricity bills. Further, energy efficient
operation has been a top social obligation from an environmental
and global viewpoint.
Q. How are efficiency and power factor
correlated?
Due to continuous innovations made in the designs of motors,
over the years, values of efficiency and power factor in standard
motors have reached an optimum level. Thus here onwards,
unless an entirely new series of motors are made, improvement in
one adversely affects other. That is, in standard motors, an
attempt to improve efficiency normally results in lower power
factor and vice-versa.
Q. What is efficiency based design (EBD) and
what is power factor based design (PFBD) ?
Around the world, in standard series motors, there are two design
philosophies. One is called "Efficiency Based Design (EBD)" and
the other is called "Power Factor Based Design (PFBD)". In the
former case, the basic design including stamping designs are
optimised for maximising efficiency, while retaining power factor
to reasonably acceptable level. Where as in the latter case, it is
otherwise.
Q. What is the difference in electromagnetic
parameters in case of the above two designs?
EBDs are based on lower losses and hence lower resistances.
Lower resistance in the circuit could lead to lower power factor.
Where as PFBDs have higher rotor resistances.
Q. How EBDs and PFBDs compare on other
performance parameters?
Since EBDs have lower rotor resistances, the starting torque
could be lower. To compensate this, flux level might go up leading
to higher magnetic current.
Q. How about starting current?
Starting current is dependent on stator and rotor leakage
reactances and resistances. Since leakage reactances and
resistances are lower for EBDs, the starting current is likely to be
higher as compared to the case of PFBDs.
Q. What is no-load current and why is one
concerned about it?
No-load current is a quality control parameter used to check
health of motor as per design and manufacturing practice. It is a
normal practice to provide this data to the customer for each
motor, so that the motor could be subjected to routine test, as and
when required.
Q. What is the normal value of no-load current?
There is no standard value of no-load current. It depends on the
design philosophies and manufacturing practices. This parameter
is in-fact manufacturer specific and its value varies widely from
manufacturer to manufacturer. Further, pole number and size of
motor greatly influence values of no-load current. Value of no-load
current can vary from 20% of full load current for 4 pole motors to
80% for 8 pole motor. Similarly, in smaller motors the value of no-
load current as a percentage of full load current is much higher as
compared to larger motors. In smaller motors of higher pole
numbers, there are cases where no-load current is higher than full
load current.
Q. How is no-load current related to the design
philosophy?
Since EBDs use magnetic circuit more optimally than electric
circuit, the magnetising current could be higher as compared to
PFBDs. This could lead to higher no-load current in EBD designs.
Q. Is there any adverse effect of higher no-load
current on the motor?
No, if the motor is designed for higher no-load current, it would
have no effect on its declared performance and life.
Q. Does higher no-load current design affect
other performance parameters?
Only in a few cases, the rated current of EBD motors could be
slightly higher than that of PFBD motors. Since the motor is
designed for the rated current, declared performance is
guaranteed. But in terms of input kW, EBD motors would result in
lower electricity bills. After all it must be understood that no-
load current is a quality control parameter and not a
performance parameter.
Q. Why EBDs are more popular than PFBDs ?
Both efficiency and power factor can be built into the motor. But
once the motor is built, efficiency can not be improved by external
measures, though, power factor can be improved by using
capacitors. Hence, the usual practice is to maximise the motor
efficiency at design stage and improve power factor at operational
stage i.e. by capacitors. A case study of benefits in energy saving
by employing EBD motor is illustrated below for 3 number 30kW
/4pole motors in a pump application.
Parameter PFBD EBD
motor motor
Efficiency, % 90 92.5
Power factor 0,89 0.83
Ampere= Rated kw/(sqrt(3)xVxEffxPower factor) 52 54
Input power=Rated Power*100/Eff, kW 33,333 32.432
Pdiff=Difference in Input Power, kW 0.901
Energy saved/year, kWh=Pdiff x No. of hours/yr
when each pump runs 8 hr/day 7081
kWh = Pdiff x 7860
Saving in Rs., @ Rs.3.50/- per kWh 24784
37
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