Motor Workshop Presentataion Files. English

Discrete Automation and Motion Division, May 27 2015
ABB Technical Workshop on Motors

and Generators
ABB
May 26, 2015
| Slide 1
Agenda
Chng trnh
Time - Thi gian
08:30 09:00
9:00 09:15
9:15 10:45
Content - Ni dung
Registration - Dong Nai Meeting Room - 12B Floor - Khch mi ng k - Phng ng Nai - Tng 12B
Ta nh REE
Opening speech - Introduce VNABB - Discrete Automation and Motion Division- Motors and Generators
Business Unit Pht biu m u chng trnh - Gii thiu ABB Vit Nam-Ban Thit b T ng ha v
Truyn ng in- B phn ng c
Basic motor technical information + ABB safe area motors portfolio - K thut c bn ng c in +
ng c in khng s dng trong vng nguy hi
Basic hazardous area information + ABB hazardous area motors portfolio - Cc loi ng c & thng s
s dng trong mi trng nguy him
10:45 11:00
11:00 12:00
11:45 12:00
13:00 13:30
13:30 15:15
Break - GIi lao

MV motor information + ABB portfolio - Tng quan v ng c trung th ABB
Lunch - Buffet tra
ABB Drive - Bin tn ABB
ABB Dimensioning Tools (MotSize+DriveSize) with exercises
Cc cng c o lng kch c bin tn, ng c (Drivesize, Motsize)
15:15 15:30
15:30 16:30
Break - Gii lao

NEMA+ MPT + NEMA vs IEC + Service
ng c Nema + Sn phm truyn ng in c khi
Dch v k thut
16:30 17:00
ABB
May 26, 2015
| Slide 2
Q&A & wrap up - Hi p & Kt thc chng trnh
Agenda
Chng trnh
Time - Thi gian
08:30 09:00
9:00 09:15
9:15 10:45
Content - Ni dung
Ta nh REE
10:45 11:00
11:00 12:00
11:45 12:00
13:00 13:30
13:30 15:15
Break - GIi lao

Lunch - Buffet tra
15:15 15:30
15:30 16:30
Break - Gii lao

Dch v k thut
16:30 17:00
ABB
May 26, 2015
| Slide 3
Richard Yue, Discrete Automation and Motion Division, May 27 2015
Introducing ABB
ABB
May 26, 2015
| Slide 4
A global leader in power and automation technologies

Leading market positions in main businesses
~140,000
40
$
billion
In revenue
(2014)
employees
Present
in
Formed
in
~100
1988
countries
merger of Swiss (BBC, 1891)

and Swedish (ASEA, 1883)
engineering companies
Power and productivity for a better world

ABBs vision
A leader in addressing power

infrastructure and control needs
for utilities, industry and transport
& infrastructure
A leader in operational asset

effectiveness uptime, speed,
yield and efficiency
Update
Contributing to decoupling growth from environmental impact
ABB
| Slide 6
Less energy per unit GDP
Less pollution per unit energy
How ABB is organized

ABB Group: Five global divisions
Power Products
Power Systems
$10 billion
35,400 employees
$7 billion
18,900 employees
Discrete Automation
and Motion
$10 billion
31,100 employees
Low Voltage
Products
Process
Automation
$7,5 billion
29,900 employees
$8 billion
23,100 employees
(2014 revenues)
ABBs portfolio covers:

Electricals, automation, controls and
instrumentation for power generation
and industrial processes
Motors and drives
Intelligent building systems
Power transmission
Robots and robot systems
Distribution solutions
Low voltage products
Services to improve customers productivity

and reliability
ABB
| Slide 7
ABB Vietnam Introduction
October 31,
2013
ABB in Vietnam
Hanoi
Bac Ninh
Headquarters:
Orders 2014:
Revenues 2014:
Total Workforce:
Hanoi
144 MUSD
153 MUSD
Over 850
4 Divisions:
Da Nang
Power Products
Low Voltage Products
Discrete Automation and Motion
Process Automation.
HCMC
VNABB is one of the Top 20 companies to work for in Vietnam.

In the category Engineering VNABB is #3
Source: Anphabe Vietnam online Network of Management Professionals
ABB Group
May 26, 2015 | Slide 9
ABB in Vietnam
Business Profile
DM and LP are growing fast and promising

PA is growing and the potential market is
significant
Factories:
Transformers SPT: Power transformers up to 63MVA
Transformers DT:
Distribution transformer up to
12.5MVA
High Voltage:
Interrupters and Spacers
Medium Voltage:
MV switchgear (ZS1) and Compact
Secondary Substation (CSS)
Discrete Automation and Motion

Driving customers industrial
productivity and energy efficiency
October 31, 2013
Business units and offering
Drives and Controls
Low voltage AC drives from

0.12 to 5600 kW
ServoDrives and controls,
linear Motors
Medium voltage drives from
315 kW to more than 100 MW
DC Drives from 4 kW to 15000
kW
PLCs, HMIs
Software tools
Product Packages Based on
Drives and PLC offerings
Service
October 31, 2013
Motors
and Generators
Power Conversion
Excitation and synchronizing

systems
High power rectifiers
DC wayside power solutions
Power quality and power
protection products, including
UPS
Traction converters
Wind turbine converters
Solar inverters
EV charging infrastructure
Service
Low voltage motors from 0.25

to 1000 kW
High voltage motors and
generators up to 70 MW
High speed motors
Traction motors
Wind power generators
Diesel generators
Gas and steam turbine
generators
Hydro generators, tidal waves
Mechanical power transmission
Service
Robotics
Industrial robots
Robot controllers and software
Industrial software products
Application equipment and
accessories
Robot applications and
automation systems for
automotive, foundry,
packaging, metal, solar, wood,
plastics, etc. industries
Service
Which market do we serve?

Over $ 130 billion market
Discrete manufacturing
Hybrid/batch manufacturing
Process industries
Utilities
$42,162
$10,556
$33,145
$11,113
Transportation equipment
Infrastructure, buildings
Electric vehicles
Renewable energy
$15,551
$7,614
$385
$10,698
2013 global market value in US$ million
BU Motors and Generators
April 9, 2015
What we stand for

Our beliefs
We are to be the best - as determined by our customers marketers, designers and manufacturers of industrial electric
motors, generators and mechanical power transmission
products.
With expertise, and a comprehensive portfolio of products
and life-cycle services, we help value-minded industrial
customers improve their energy efficiency and productivity.
ABB
| Slide 15
Who we are
Business unit Motors and Generators
ABB
April 9, 2015
| Slide 16
Employees
About 16,000
Presence
More than 100 countries
Manufacturing
41 factories in 11 countries
Service
65 ABB service centers and more than

100 authorized service providers
Channels
5,600 ABB external channels
Stocks
1,600,000 products in 7 logistic centers
What we do
Complete product offering one place to buy
IEC motors
Low voltage high efficiency
motors
High voltage induction and
synchronous motors
Motors for explosive
atmospheres
Permanent magnet motors
DC motors
Traction motors
Motors for marine applications
Synchronous reluctance motors
Servomotors
Motors for variable speed
applications
ABB
April 9, 2015
| Slide 17
NEMA motors
Low voltage high efficiency
motors
High voltage induction and
synchronous motors
Motors for explosive
atmospheres
Washdown motors
DC motors
Traction motors
Motors for marine applications
Servomotors
Motors for variable speed
applications
Mechanical power
transmission products
Generators
Induction and synchronous wind
power generators
Synchronous generators for
diesel and gas engines
steam and gas turbines
marine applications
industrial applications
Synchronous condensers for
reactive power compensation
Traction generators
Mounted bearings
Enclosed gearing
Mechanical drive components
Couplings
Sheaves and bushings
Conveyor components
Geared motor units
What we do
supported by world class services
Installation,
commissioning,
maintenance and
condition monitoring
Repairs, replacements,
upgrades
and refurbishment
Spares and consumables
Advanced services,
trainings and
service agreements
Faster start-up, optimized life cycle

maintenance and early detection of
potential faults
Improved efficiency, reliability and

safety
Increased availability and minimized

downtime
Maximized performance, reduced

risk and delivered know-how
Certified, experienced
commissioning engineers
Proven four-level maintenance
program
Remote and on-site condition
monitoring solutions
Regular health checks for critical
equipment
On-site and workshop repairs by

fully trained personnel
Direct replacements for older
units
Upgrades of old equipment with
latest technology
Turnkey component upgrades
Local support through global
service organization
Genuine OEM spare parts and

support
Efficient on-line order processing
and tracking system
Individual components, tailored
packages and maintenance kits
Support in rationalizing on-site
spare part stocks
Analyze energy, performance

and reliability costs
Support for long-term planning
including risk assessments and
training programs
Access to ABBs extensive
knowledge base
Single agreement for easy
management
ABB
April 9, 2015
| Slide 18
Our products work in all industries, all applications
ABB
April 9, 2015
| Slide 19
Agenda
Chng trnh
Time - Thi gian
08:30 09:00
9:00 09:15
9:15 10:45
Content - Ni dung
Ta nh REE
10:45 11:00
11:00 12:00
11:45 12:00
13:00 13:30
13:30 15:15
Break - GIi lao

Lunch - Buffet tra
15:15 15:30
15:30 16:30
Break - Gii lao

Dch v k thut
16:30 17:00
ABB
May 26, 2015
| Slide 21
Chiam Chee Seong

27th May 2015
Basic Motor Technical &

Non-Hazardous Area Motors Portfolio
ABB BU Motors and Generators
May 26, 2015 | Slide 22
Component Parts of a Motor
Terminal cover
Fan
cover
Terminal block
Terminal box
Stator core
Fan
N-End-shield+bearing
D-End-shield+bearing
Stator house
Rotor
Shaft

May 26, 2015 | Slide 23
Stator winding
The Making Process
Punching
Stator manufacturing
Winding
Rotor casting
Coupling
Stitching
Impregnation
Testing
Packing

May 26, 2015 | Slide 24
Rotor assembly
Assembly
Insulation
In a LVAC electrical motor there are

May 26, 2015 | Slide 25
Wire insulation (Enamel Insulation)
Slot insulation
Insulation (Cont.)
Slot cover or slot wedge
Phase insulation

May 26, 2015 | Slide 26
Insulation (Cont.)
Layer insulation
Tying or lacing band

May 26, 2015 | Slide 27
Impregnation
Trickle impregnation (applied on frame 280 and above)

Heating during rolling:
20C/min, temperature in the
end of the rolling 130 - 140C
(epoxy 160C)
Stoving:
Temperature of the stove
150oC, stoving time 50 min

May 26, 2015 | Slide 28
Impregnation
Vacuum impregnation (applied on frame below 280)

Vacuum sucks the resin into
winding
Impregnation time 45 min
No heating during
impregnation
Stoving:
Temperature of the stove
140oC, stoving
time 4 h

May 26, 2015 | Slide 29
IEC Motor Mechanical Design

Frame Construction
Modern totally enclosed squirrel cage motors are available in a choice of

aluminum, steel and cast iron frames for different application areas.
Available frame materials for ABB motors are cast iron and aluminium.
Frame Size
- The height of shaft center point in
relation to the surface of the ground
(typically measured in mm).
- Common IEC frame sizes for LV
motors are 56, 63, 71, 80, 90, 100, 112,
132, 160, 180, 200, 225, 250, 280, 315,
355, 400 and 450.

May 26, 2015 | Slide 30
Mounting Arrangements

May 26, 2015 | Slide 31
There are Code I and Code II

for motor mounting
arrangements. Marked *)
means its not specified in IEC
60034-7.
Mounting arrangement is very

important to manufacturer as
there might have some special
consideration required
especially for vertical mounted
motors (eg: V3, V6, V1.)
Special end shield or seals is

required for those shaft
upwards where water/liquid
are expected to go down along
the shaft.
Cooling Type

November 4, 2010 | Slide
Cooling Type (Cont)

Cooling Type (Cont)

Degree of Protection (IP/IK)

May 26, 2015 | Slide 35
Terminal Boxes

May 26, 2015 | Slide 36
Bearings
ABBs LV motors are provided with deep groove ball bearings as standard. The
complete bearing designation is stated on rating plate of most motor types.
Bearing selection is based on forces from load towards to bearings (eg: axial force,
radial force and thrust force). Its advisable to provide the force value, mounting ,
direction and magnitude to ABB for precise verification.
Common bearing selection on applications below:Roller bearing High radial force (eg: belt, conveyor)
Angular contact bearing High thrust force (eg: vertical mounted..)
The normal life L10 of a bearing is defined, according to ISO, as the number of
operating hours achieved or exceeded by 90 per cent of identical bearings in a large
test series under certain specific conditions. 50 per cent of the bearings achieve at
least five times this figure.
Insulated bearing is needed for VSD motors, please refer to VSD section for more
information.

May 26, 2015 | Slide 37
Enclosure Surface Treatment and Colour
All the painting system are according to ISO/EN 12944 standard.

ISO/EN 12944 divides durability into 3 categories: Low (L), Medium (M), and High
(H) where Low (L) durability corresponds to 2-5 years, Medium (M) 5-15 years and
High (H) more than 15 years.
All the ABB motors are treated with Medium (C3M) surface treatment and Munsell
Blue 8B 4.5/3.25 paint colour as standard. Others painting systems are available
upon request.

May 26, 2015 | Slide 38
Vibration
Vibration according to Grade A is applied to ABB motors as standard.
The vibration measurement is performed for all motors and generators according to
IEC 60034-14.
Grade B vibration level is available upon request.

May 26, 2015 | Slide 39
Basic Information for Dimensioning (DOL)

May 26, 2015 | Slide 40
Supply: Voltage, frequency, and its variation
Load: Torque vs Speed curve, application, speed
Environment: Safe/Ex, ambient temperature, altitude
Standard/ specification: IEC/NEMA, Marine, and etc.
Additional requirements: Mounting, cooling, IP rating.
Terminology - Basic Formulas

May 26, 2015 | Slide 41
Permissible Temperature Rise

May 26, 2015 | Slide 42
Torque vs Speed Curve

May 26, 2015 | Slide 43
Starting Type

May 26, 2015 | Slide 44

VSD Motors

May 26, 2015 | Slide 45
65% of electricity used in industry is

absorbed by electrical motors
20% of this energy is dissipated by

losses of electrical motors
The use of best technology

(including high efficiency motors, use
of drives etc.) would lead to a
reduction of emission of CO2 by 68%
from 23,500 Mton/year down to
7,500Mton/year

Major Benefit of using VFD
PERFORMANCE CONTROL
AC drives are used to bring process and quality improvements in industrial
applications through drives' control superiority in terms of key parameters including
acceleration, flow, monitoring, pressure, speed, temperature, tension and torque.
Energy Saving
AC motor-driven applications that do not require full speed can save energy by
controlling the motor with a variable speed drive.
Energy cost saving with variable torque can be significant, often paying for the cost
of VFD within a matter of months for some specific applications(e.g. variable
speed fan, pump).

May 26, 2015 | Slide 46
Made in ABB
VSD motor characteristics - Comparison with constant
speed motor
Constant speed motors
Starting current surge up to more

than 8 times nominal current, and
hence a big voltage drop on
network. Sometimes this
phenomena might cause motor
starting failure or network black out
Consideration of the heating during
start is inevitable, and hence a
limited number of consecutive
starts.
Starting torque could be a problem
sometimes for high load torque and
high inertia application

May 26, 2015 | Slide 47
VSD motors (Advantage)
Current will be well controlled

around nominal current, and hence
much less impact to the network.
No extra attention needed for the

thermal stress during starting, and
no limitation on number of
consecutive starts due to thermal
problem.
Starting torque is close to maximum

torque, making start easy
VSD motor characteristics - Comparison with constant speed

motor
Constant speed motors
Having only one operating point

(speed and power), hence, sizing is
made only to that one point.
Sinusoidal input, no extra heating

due to harmonic distortion.
Sinusoidal input, no extra

insulation requirements due to
voltage peaks.
Sinusoidal input, no extra

insulation for bearing needed.
Sinusoidal input, noise level

relatively low

May 26, 2015 | Slide 48
VSD motors (Extra Consideration)
Having an operating range (speed and

power), hence, sizing is made to the whole
range, including the relationship between
critical speed and the operating speed
range, and the need to enhance the
cooling at low speed range.
Extra insulation might be needed due to

voltage peak
Extra insulation needed for bearing

because of the shaft voltage caused by the
inherent association with high frequency
voltage
Might cause higher noise level hence

might need to consider noise control
Additional Consideration for VSD Driven Motors
More Information of Variable Speed Operation
Safe Area Motors Loadability & Cooling Type (Motor)
Winding Insulation (Motor) and Filtering (Converter)
Insulated Bearing (Motor)
Hazardous Area (Motor)
Hazardous Area Motors Loadability
Others

More Information for VSD Motors
What is the load type/ application?
What is the operating speed range?
What is the VSD power required?
Is there any overload condition? If yes, what is the duration?
Which drive to be used?

May 26, 2015 | Slide 50
Process performance motors

VSD - Loadability curves
ACS800/50 Hz, temp rise B

May 26, 2015 | Slide 51
Based on comprehensive tests
With separate cooling full 100%

loadability possible also at low speeds
The curve shows loadability of

process performance motor on
converter duty as a relation to nominal
torque
This loadability curves represent only

the thermal loadability. Other factors
may also limit the loadability (i.e. the
max. Allowed speed of the motor)

VSD Insulation and filtering
Nominal supply voltage UN
of the converter
UN 500 V
UN 600 V
Winding insulation and filters required

ABB Standard insulation
ABB Standard insulations with du/dt-filters at
converter output
OR
UN 690 V
ABB Special insulation

(variant code 405)
(variant code 405)
AND
UN 690 V AND
cable length > 150 m

May 26, 2015 | Slide 52
du/dt-filters at converter output

(variant code 405)
What will Happen if Incorrect Winding Insulation Applied for

Continuous VSD Application?

May 26, 2015 | Slide 53
Insulated Bearing on VSD Driven Motor

Common mode voltages of voltage source of converters are causing high
frequency bearing currents
IN V E R T E R
2
1
M O TOR C ABLE
MOTOR
GEAR
LO A D
4
7
+D C
C o m m on m od e
v o ltag e p u ls e
-D C
H ig h fre q u en c y
com mon m ode
c u rre n t
H ig h fre q ue n c y
sh a ft v o ltag e
P E -cu rren t
H ig h fre qu e n c y
fra m e v o ltag e
H ig h fre q ue n c y
circ u la tin g c u rre n t
ABB BU Motors and Generators May

26, 2015 | Slide 54
S h aft g ro u n d in g cu rre n t
Insulated Bearings and Filters
Use of non-suitable bearings, the surfaces of rolling elements and raceways in the
bearing might be damaged and degrade the grease rapidly (electric erosion). This is all
due to common shaft current from converter supply.
Bearing voltages and currents must be avoided with insulated bearings (VC+701) and/or
properly dimensioned filters at the converter must be used as shown in guideline table
below:
Nominal power PN
and/or IEC frame size
Preventive measures
PN < 100 kW
No actions needed
PN 100 kW
OR
IEC 315 Frame size IEC 355
Insulated non-drive end bearing

(VC+701)
PN 350 kW
OR
IEC 400 Frame size IEC 450
Insulated non-drive end bearing

(VC+701) AND
Common mode filter at the converter

May 26, 2015 | Slide 55

VSD Insulated bearing

May 26, 2015 | Slide 56
Bearing currents in VSD duty can damage the

surfaces of rolling elements and raceways in the
bearing and degrade the grease rapidly (electric
erosion)
Insulated bearing eliminates the bearing currents

Longer bearing lifetime less maintenance
Several hundred of tests at site show that it is only

needed on N-end
Outer ring plasma spray coated and further treated

to make it insensitive to moisture and humidity
Only high quality insulated bearings are used
Sample Damages of Shaft Current to Conventional

Bearings

May 26, 2015 | Slide 57
Process Performance Motors

May 26, 2015 | Slide 26
Low voltage
Motors for the most demanding

continuous process applications
Tailor-made to meet the individual

needs of applications
Prepared to answer any reliability,

availability and energy efficiency
challenge, both now and in the future.
Fulfilling IE2-IE3-IE4 efficiency class,

available from stock*
* Depending on warehouse

May 26, 2015 | Slide 59

Range
Sizes 71-450
56 63 71
80
90
100
112
132
160
180
200
225
250
280
315
355
400
450
180
200
225
250
280
315
355
400
450

56 63 71
80
90
100
112
132
160
IE2 High efficiency aluminum motors (M3AA)
IE2 High efficiency cast iron motors (M3BP)
IE3 Premium efficiency motors M3BP (Aluminum M3AA <250)

IE4 Super premium
efficiency motors M3BP
IE2 aluminum M3AA: Output 0.12 kW to 90 kW **

IE2 Cast Iron M3BP: Output 0.25 kW to 1 MW **
IE3 Cast iron M3BP: Output 0.75 to 375 kW **
May 26, 2015 | Slide 60
IE4 Cast iron M3BP: Output 75 to 375 kW **
** Depending on pole number and frame size
General Performance Motors

May 26, 2015 | Slide 32

Range
ABB /BU Motors and Generators
May
26, 2015 | Slide 33

Cast Iron Motors
New optimized General Performance cast iron

motors cover the needs from various industrials,
designed on global R&D platform with wider
variants feasibility compared to existing units.
This allows motors running on demanding VSD
operations.
Fulfilling IE2 efficiency class, premium efficiency

IE3 is available upon request.
Output
Type
Frame sizes
0.18 kW to 355 kW**

M2BAX
71 to 355 Cast Iron
ABB I BU Motors and Generators

May 26, 2015 | Slide 34

Aluminium Motors
General Performance IE2 high efficiency

aluminum motors, suited for applications
where simplicity and off-the-shelf availability
are paramount. With ABB quality and
support, these motors have the features
appreciated by volume customers and serial
OEMs.
Fulfilling IE2 efficiency class, available from

stock*
Output
Type
Frame sizes
0.06 kW to 55 kW**
M2AA
56 to 250 Aluminum
* Depending on warehouse

May 26, 2015 | Slide 35

Structure
Main differences M3 M4
Frame, feet
Lifting lugs
Foot design
Earthing terminals
Support
Knowledge and expertise
Stock
Options, variant codes
Traceability
Rating plate
Documentation
End shields
After sales
Drain holes
Terminal box
Fan, fan cover
Cooling
Lifecycle
Efficiency
Bearings, sealings
Regreasing plate
Electrical design
Surface treatment

May 26, 2015 | Slide 65
Applications
VSD
Typical
industries
Multiple Choice of Variants (Process Performance)

May 26, 2015 | Slide 66

Documentation

May 26, 2015 | Slide 67
Available from web sites in ABB standard

format
EC declarations of conformity
Dimensional drawings
2D and 3D CAD drawings
Connection diagrams (Basic)
O & M Manual
Available on request:
Data sheet
Performance curves incl. torque-speed
curves
Routine test certificates
Environmental certificates
Noise spectrums
Type test reports
Test together with frequency converters
High Efficiency Motors

May 26, 2015 | Slide 68
65 % of total electricity at industrial sites

is consumed by electric motors
Motor purchasing price corresponds to 8

to 12 weeks of its electricity consumption
The capital cost will represent only 1% of

the total life cycle operational costs of the
motor
Reliable motors with a high efficiency

level ensure the lowest life cycle costs
Energy Efficiency and Carbon Footprint Reduction

Energy facts about LV motors
78.8 kW
81.4 kW
Loss
3.8 kW
Efficiency = 95.1 %
Reduced losses = 2.6 kW
75 kW
Loss
6.4 kW
Efficiency = 92.1 %
If the efficiency level increases with 3 %-units, the reduction of losses is 40%
Annual savings = 2.6 kW x 0.055 EUR* x 8760 hrs = 1251 EUR / 11 tonnes CO2 (0.5 kg/kwh)
Annual savings = 2.6 kW x 0.07 USD* x 8760 hrs = 1594.32 EUR / 11 tonnes CO2 (0.5 kg/kwh)
May 26, 2015 | Slide 69
* Sample tariff rate
New efficiency classes defined by IEC/EN 60034-30
Super premium efficiency *
IE4
Super premium efficiency
Premium efficiency
IE3
Premium
High efficiency
IE2
Comparable to EFF1
Standard efficiency
IE1
Comparable to EFF2
*) IE4 level for asynchronous and synchronous motors defined by

IEC 60034-31: 2010 Technical specification

May 26, 2015 | Slide 70
Timeline for the EU MEPS
Note!
IE classes required
by the regulation
correspond to IE
class defined in
IEC/EN 60034-30
standard
Phase 1:
From 16 June,
2011
Phase 2:
From 1 January,
2015
Phase 3:
From 1 January,
2017

May 26, 2015 | Slide 71
Motors with specification below must

meet the IE2 efficiency level:0.75kW-375kW, 2-6 poles, up to 1kV
50Hz
Motors with a rated output of 7.5 375
kW must meet EITHER the IE3
efficiency level OR the IE2 level if fitted
with a variable speed drive
Motors with a rated output 0.75 375
kW must meet EITHER the IE3
efficiency level OR the IE2 level if fitted
with a variable speed drive
Process performance cast iron motors

Structure - Rating plate, more examples for different motor sizes
Motor sizes 71-90
Motor sizes 100-132

May 26, 2015 | Slide 72
Motor sizes 160-250

LV Motor Manufacturing and Central Stock Locations
Vsters,
Sweden
Vsters, Sweden
Central Stock North
Vaasa,
Finland
Menden, Germany
Central Stock Europe
Shanghai,
China
Shanghai,
Central Stock North
Asia
Barcelona, Spain
Central Stock South
Manufacturing
Central stocks

May 26, 2015 | Slide 73
Lodz,
Poland
Singapore,
Central Stock South
Asia
Faridabad
&
Bangalore,
India
Some Customer Segments
Chemical &
Petrochemical
Water & waste water
Metals & mining
Oil & Gas
Food & Beverage
Pulp & paper
Steel

May 26, 2015 | Slide 74
Cranes & Marine
Rail

May 26, 2015 | Slide 75
Chiam Chee Seong

27 May 2015
BU Motors & Generators
Hazardous Area Information &

Motor Portfolio
Hazardous Area Motors

Explosive atmosphere - Classification
Explosive atmospheres are classified into groups:
Group I
gas
gas
Group II
Group III
Mines full of
firedamp were the
first plants at risk
Industries like
chemical plants,
petrochemical,
industries or
products storage,
dust
May 26, 2015 | Slide 77

Explosive atmosphere Group II
n
According to European Directives 94/9/EC (ATEX), IEC 60079-10, EN 60079-10 and NEC 505,
explosive atmospheres are classified, relating to the presence probability of flammable
substances, in ZONES:
Zone 0
( Gas presence > 1000 hours/year)
n
Presence during
normal operations
Zone 1
( Gas presence 10 - 1000 hours/year)
n
Area where an explosive gas mixture is

present continuously, for long period or
frequently (Zone 20 for dust)
Continuous
presence

likely to occur under normal operations
(Zone 21 for dust)
Zone 2
( Gas presence < 10 hours/year)
n

unlikely to occur (or occur only under
abnormal conditions) (Zone 22 for dust)

May 26, 2015 | Slide 78
Presence just
in case of failure or
abnormal operations

Area Classification
Zone
Zone
Example:
May 26, 2015 | Slide 79
Tanker lorry loading units
2
1

Explosive Atmospheres
Classification of gases and vapours
in explosion groups and temperature classes
T1
T2
Methane
IIA
Acetone
Ethane
Ethylacetate
Ammonia
Benzol
Acetic Acid
Carbon monoxide
Methanol
Propane
Toluene
Ethylalcohol
I-amyl acetate
N-buthane
N-btylalcohol
IIB
Town gas
(lamp gas)
Ethylen
IIC
Hydrogen
Acethylene
T3
T4
T5
T6
Petrol
Diesel fuel
Aviation fuel
Heathing oil
N-hexane
Acetaldehyde
Comparison between Division and Class Grouping
Typical Gas
Carbon
disulphide
Based on these values the appropriate temperature class

will be determined for an equipment installed safely in the
area containing a combustible substance which does not
exceed the auto-ignition temperature of the substance. This
temperature class is mostly not exceeding 80% of the AIT,
and in many industries may be even lower to provide a
bigger safety margin.
Diivision System
NEC 505
Zone System
EN & IEC
Acetylene
Group A
Hydrogen
Group B
Ethylene
Group C
Group IIB
Propane
Group D
Group IIA

May 26, 2015 | Slide 80
Group IIC
Relationship Between Gas/Dust Subdivisions

and Equipment Groups
Location gas/dust
subdivision
Permitted equipment group
IIA
IIA or IIB or IIC
IIB
IIB or IIC
IIC
IIC
IIIA
IIIA or IIIB or IIIC
IIIB
IIIB or IIIC
IIIC
IIIC

May 26, 2015 | Slide 81

IEC and EN Standards (Former Edition)
T1
T2
T3
T4
T5
T6
450C
300 C
200 C
135 C
100 C
85 C

May 26, 2015 | Slide 82
Apparatus groups
Group I - mines susceptible to firedamp
Group II - other places
Gas group (needed only for Ex d and Ex i)
IIA (e.g. Propane)
IIB (e.g. Ethylene)
IIC (e.g. Acetylene and Hydrogen)
Determination of Zone (presence of explosive

atmosphere)
Zone 0/20
- continuously or for long periods or frequently
Zone 1/21
- in normal operation occasionally
Zone 2/22
- not in normal operation, but if it does occur,
will persist for a short period only
Temperature classes

IEC and EN Standards (Newest Edition)
T1
T2
T3
T4
T5
T6
450C
300 C
200 C
135 C
100 C
85 C

May 26, 2015 | Slide 83
Apparatus groups
Group I - mines susceptible to firedamp
Group II areas with gas
Group III areas with dusts
Gas group (needed now for all )
IIA (e.g. Propane)
IIB (e.g. Ethylene)
IIC (e.g. Acetylene and Hydrogen)
Dust group (needed now for dust as well)
IIIA (combustible flyings, eg. fibers)
IIIB (non-conductive dust)
IIIC (conductive dust)
Determination of Zones as before
Temperature classes as before

Equipment Protection Levels (EPL)
EPL
Definition
Ga (gas)
Equipment having a very high (a) level of protection, e.g. ia
Gb (gas)
Equipment having a high (b) level of protection, e.g.ib, d,

p, e,(de)
Gc (gas)
Equipment having an enhanced (c) level of protection, e.g.

ic,nA
Da (dust)
Equipment having a very high (a) level of protection, e.g. ta
Db (dust)
Equipment having a high (b) level of protection, e.g. tb
Dc (dust)
Equipment having an enhanced (c) level of protection, e.g. tc

May 26, 2015 | Slide 84

Equipment Protection Level (Cont)
EPL
Zone
Ga
Gb
Gc
Da
20
Db
21
Dc
22

May 26, 2015 | Slide 85
Traditional relationship of
EPLs to zones
No additional risk
assessment done or
necessary if used according
to table

ATEX and IEC Standard
Standars
EN 60079-0
IEC 600790
General Rules for all Ex Motors
EN 60079-2
IEC 600792
Pressurised
p
EN 60079-1
IEC 600791
Flame Proof
d
EN 60079-7
IEC 600797
Increased Safety
e
EN 60079-15
IEC 6007915
Non Sparking
n
Zones
ZONE 1
ZONE 2
Motor category (ATEX only)

Category 2
M
G
May 26, 2015 | Slide 86
Category 3

Non Sparking Motors (Ex nA)
n
What does it mean Non Sparking enclosure ?

n
Parts which could ignite an explosive gas are manufactured in

such a way that to prevent ignition of flammable gas
ABB standard certified for ExnA IIC T3
No spark in
normal conditions
(outside and inside)
No dangerous hot
surfaces in normal
conditions (outside and
inside)

Increased Safety Motors (Ex e)
n
What does it mean Increased Safety enclosure?

n
Parts which could ignite an explosive gas are manufactured in

such a way that to prevent ignition of flammable gas
No spark in normal/
fault conditions
(outside and inside)
No dangerous hot
surfaces in all
conditions (outside
and inside)

Flameproof Motors (Ex d)
n
What does it mean Flameproof enclosure ?

n
The enclosure is designed in such a way that an explosion inside

the motor will not cause any permanent deformation and will
prevent the flame propagation outside
No spark in normal
and fault conditions
(outside)
No dangerous hot
surfaces in all
conditions (outside)
strong housing
(frame and shields)
seals and labyrinths

Pressurized Motors (Ex p)
n
What does it mean Pressurized enclosure ?

n
Parts which could ignite an explosive gas mixture are housed in

an enclosure which is flushed and pressurized by a protective
gas, e.g. clean air
po
No spark in normal and
faul conditions
(outside)
Inlet
inert gas
Outlet
inert gas
p > po
No dangerous hot
surfaces in all
conditions (outside
and inside)

Dust Ignition Proof Motors (Ex tD)
n
What does it mean protection by enclosures?

n
The enclosure is designed in such a way that dust can not

penetrate inside enclosure (at all IP65 or harmful amount IP56).
No spark in
normal conditions
Zone 22 (outside)
No dangerous hot
surfaces in normal
conditions Zone 22
(outside)
Enclosure IP
classification
seals and labyrinths

May 26, 2015 | Slide 91

Certification

May 26, 2015 | Slide 92

Certification
CSA/CEC
Code
EN
JI
S
NEMA /
NEC
AS/N
ZS
M
G
May 26, 2015 | Slide 93
Certifications used as global
IEC certificate
IECEx Scheme certificate
ATEX certification
CSA certification
Typical national certifications
GOST to Russia
Inmetro to Brazil
CNEx for China
KOSHA for Korea
CCE / DGFASLI for India
ABB the first to use the IECEx conformity mark
ABB BU Motors and

Generators May 26, 2015 |
Slide 94
ABB is the first motor

manufacturer to be granted
a licence to use the IECEx
conformity mark
Globally certified, with

global support and certified
service

Portfolio
Flameproof Ex d/Ex de
IEC 80-710, up to 4500 kW
Increased safety Ex e
IEC 80-500, up to 1500 kW
Pressurized Ex px/Ex pxe

IEC 355-2500, up to 60 MW
Non-sparking Ex nA
IEC 71-2500, up to 60 MW
Class I Div 2/Zone 2

up to 60 MW, 80000 HP
kW
LV motors
HV Cast iron frame

May 26, 2015 | Slide 95
HV Welded frame
Synchronous
100
1000
10000
100000

Product Portfolio (LV)
Sizes 56-450
56 63 71
80
90
100
112
132
160
180
200
225
250
280
315
355
400
450
160
180
200
225
250
280
315
355
400
450
Hazardous area motors

56 63 71
80
90
100
112
132
Flameproof motors: M3JP (Ex-d); M3KP (Ex-de)
Increased safety motors: M3HP (Ex-e)
Non-sparking cast iron motors: M3GP (Ex-nA)
Dust ignition protection cast iron motors: M3GP (Ex-tD)
ABB LV motors for explosive atmospheres - PG IEC LV Motors (BU Motors and Generators)
May 26, 2015 | Slide 96

IEC/EN 60079-31 Protection by enclosure t
All general requirements about dust are in the new IEC/EN 60079-0
Specific requirements for Ex t motors are in the new standard IEC/EN

60079-31
Gaskets and seals:

May 26, 2015 | Slide 97
shall be made of one-piece continuous construction, i.e. with an

uninterupted periphery
Dust group III divided into:
IIIA for combustible flyings
IIIB for non-conductive dust
IIIC for conductive dust

IEC/EN 60079-31, terminal boxes Ex t
Terminal boxes for Ex t low voltage cast iron motors
Left image: uninterrupted gasket, permitted for new standard Ex t
Right image: interrupted gasket: not permitted !
Consequences:

May 26, 2015 | Slide 98
New terminal box designed is required on some products

New marking (IEC) gas
Ex de II B T4 Gb
Ex - Explosion protected apparatus
de - Type of Protection de
II group for gas
B gas group
Temperature class
New protection level marking for gas,

May 26, 2015 | Slide 99
b = high level of protection

New marking (ATEX, EN) gas
Marking according to ATEX-directive
II 2 G
0081
for Gas
Equipment category (Zone 1)
Equipment group for surface industry
Use in explosive atmosphere
Notified body eg. 0081 - LCIE
CE-marking
Standard marking
according to EN-standards
Type of Protection
II - Group (gas)
A, B, C - Gas groups
Temperature class
Equipment protection level for gas
May 26, 2015 | Slide 100
Ex de II B T4 Gb

New marking (IEC) dust
Ex tb III C T125C Db
tb - Type of Protection tb
III new group for dusts
C new group for conductive dust
Temperature class
New protection level marking for dust,

May 26, 2015 | Slide 101
b = high level of protection

New marking (ATEX, EN) dust
Marking according to ATEX-directive
0537
II 2 D
for Dust
Equipment category (Zone 21)
Equipment group for surface industry
Use in explosive atmosphere
Notified body eg. 0537 - VTT
CE-marking
Standard marking
according to EN-standards
Type of Protection t for dust and protection level b
III - Group (dust)
A, B, C - Dust groups
Temperature class
Equipment protection level for dust
May 26, 2015 | Slide 102
Ex tb III C T125C Db
Markings on rating plates in practice

Both IECEx and EN (ATEX) markings included
ABB BU Motors & Generators

5/26/2015
Slide 103
Ex marking according to EPL

generation of standards
Markings according to both IEC and

EN (ATEX) standards for full
flexibility
Ga = Equipment for explosive

atmospheres having a very high
level of protection
Gb = Equipment for explosive

atmospheres having a high level of
protection
Gc = Equipment for explosive

atmospheres having an enhanced
level of protection

ATEX Certified Ex Motors for VSD Applications

May 26, 2015 | Slide 104
ABBs Ex motors are tested and ATEX

certified for safe use with converters!
Safe combinations are available for several

different applications.
Contact ABB for best solution
Ex Motors Loadability Curves for ABB Frequency Converters with

DTC Control (Zone 1 & Zone 2)

May 26, 2015 | Slide 105
Ex Motors Loadability Curves for ABB ACS550 (Zone 1) and NonABB Voltage Source PWM-type Converters at (Zone 2)

May 26, 2015 | Slide 106
Ex Motors Loadability Curves for ABB ACS550 for Zone 2

May 26, 2015 | Slide 107

Manufacturing (FIMOT Vaasa, Finland)
450 km from Helsinki
Visiting address:

May 26, 2015 | Slide 108
Strmbergin Puistotie 5 A,
FI-65320 Vaasa
Factory area 34.000 m2
Focus and R&D responsibility:
Motors for frame sizes 80-132 &

280 to 450, both in cast iron.
Hazardous area motors for frame

sizes 71 to 450
Agenda
Chng trnh
Time - Thi gian
08:30 09:00
9:00 09:15
9:15 10:45
Content - Ni dung
Ta nh REE
10:45 11:00
11:00 12:00
11:45 12:00
13:00 13:30
13:30 15:15
Break - GIi lao

Lunch - Buffet tra
15:15 15:30
15:30 16:30
Break - Gii lao

Dch v k thut
16:30 17:00
ABB
May 26, 2015
| Slide 110
Koh Joon Huan, 27th May 2015
PG Large AC Motors
Technical and Product Presentation
ABB Group
May 26, 2015 | Slide 111
Standards
International standards:
IEC
(International Electro technical
Commission)
IEC 60034-XXX
Regional standards:
CENELEC
NEMA
(European Committee for

(National Electrical
Electro technical Standardization) Manufacturers
EN XXX
Association)
AMN
(MERCOSUR
Standardization
Association)
National standards:
VDE
Germany

May 26, 2015 | Slide 112
IS
India
SEN
Sweden
DIN
Germany
BS
Great Britain
IEEE
Standards
ABB strongly supports the drive to harmonise European standards and actively
contributes to various working groups within both IEC and CENELEC.
IEC defines:
Electrical:
IEC 60034-1: Rating and performance
IEC 60034-2-1: Methods for determining losses and efficiency of rotating

electrical machinery from tests *NEW!*
IEC 60034-8: Terminal markings and direction of rotation of rotating machines
IEC 60034-12: Starting performance of single-speed three-phase cage

induction motors for voltages up to and including 660V

May 26, 2015 | Slide 113
Concerning non-hazardous area motors EN standards basically follow IEC standards.

The biggest differences can be found with parts for hazardous area motors.
Standards
Mechanical:
IEC 60072-1: Dimensions and output series for rotating electrical machines - Part1: Frame
numbers 56 to 400 and flange numbers 55 to 1080
IEC 60072-2: Dimensions and output series for rotating electrical machines - Part2: Frame
numbers 355 to 1000 and flange numbers 1180 to 2360
IEC 60034-5: Degrees of protection provided by the integral design of rotating electrical
machines (IP code) Classifications
IEC 60034-6: Methods of cooling
IEC 60034-7: Classification of types of construction, mounting arrangements and terminal

box position (IM code)
IEC 60034-9: Noise limits
IEC 60034-14: Mechanical vibration of certain machines with shaft heights 56mm and
higher - Measurement, evaluation and limits of vibration

May 26, 2015 | Slide 114
Insulation classes acc. to IEC 85
Deg. C
Insulation class Maximum winding temperature

180
160
140
120
100
80
60
40
20
0
180
155
10
130
10
125
105
80
40
B
15
40
40
F
Hotspot temperature margin

Max. temperature rise
Max. ambient temperature
Motor with temp rise B is common requirement, with insulation temp rise F, [Vacuum
Pressure Impregnated (VPI), Micadur Compact resin.]
2 method to use, resistance or ETD.
A good winding should have temp rise close to even.
ABB standard using resistance method.
Motor can be tested with ETD upon request.

May 26, 2015 | Slide 115
Conditions
Ambient temperature, C
30
40
45
50
55
60
70
80
107
100
96,5 93
90
86,5
79
70
Permitted output,
% of rated output
Height above sea level, m
1000 1500 2000 2500 3000 3500 4000
Permitted output,
% of rated output

May 26, 2015 | Slide 116
100
96
92
Standard ambient temperature: -20C to +40C
Standard altitude: 1000 m above sea level
88
84
80
76
Permissible temperature rise of marine motors

May 26, 2015 | Slide 117
Classification
societies and
standards
Ambient
rise
temperature
C
Permissible temperature
K for stator windings
Insulation class
B
F
IEC Publ. 60034-1
40
80
105
IEC 92-301
50
70
90
ABS
50
70
95
BV
45
75
100
CCS
45
75
100
CR
45
75
95
DNV
45
75
100
GL
45
75
100
KR
50
70
90
LR
45
70
95
NK
45
75
100
RINA
45
75
95
RS
45
75
95
Nominal tolerances
Electric tolerances acc. to IEC 60034-1
Type
Tolerance
Note
Voltage deviation
5%
10% (+10K)
Continuous
Short time
Power factor
-1/6 of (1-cosj)
Min.0,02/Max.0,07
Efficiency
-15% of (1- h)
-10% of (1- h)
P2 < 150 kW
P2 > 150 kW
Speed
20% of guaranteed slip
Overspeed
120% for 2 min.
Start torque
-15 to + 25%
Pull-up torque
-15 %
Maximum torque
-10%
Locked rotor current (start current) +20%

May 26, 2015 | Slide 118
Min. 160% of Tn
Index of Protection (IP) Classes

IEC 60034-5
Sometimes a third digit

is used for instance
IP557 The third digit
means shock test in
Joules (ex. 7= 7
Joules)
IP W23 (W= Weather

protected ->
Customer information
to the manufacturer
required)

May 26, 2015 | Slide 119
Basic IEC Standard

IEC 60034-6 IC Code
ABB BU Motors and Generators November 4, 2010 | Slide
Basic IEC Standard

IEC 60034-6 IC Code
Rib cooled motors
IC411 is most common for lower power

motor, heat dissipate from stator to fin, fin
cool down by cooling air.
Simple cooling method, easy to install

and less maintenance.
With increase frame size, distance of

motor center with fin become larger,
cooling efficient reduce.
More cooling method with higher power.

May 26, 2015 | Slide 121
Modular motor, cooler can be change

easily, allow for different cooling
requirement.
Cooling requirement usually depend on

installation location, for a balanced
between commercial and technical
Basic IEC Standard

IEC 60034-6 IC Code
ABB Group
May 26, 2015 | Slide 122
IC 81W
IC 611
IC 01
International Standards;
IM Mounting Arrangements IEC 60034-7
Examples of common mounting arrangements

Code I
Code II
IM B3
IM 1001
IM V5
IM 1011
IM V6
IM 1031
IM B6
IM 1051
IM B5
IM 3001
IM V1
IM 3011
IM V3
IM 3031
*)
IM 3051
IM B14
IM 3601
IM V18
IM 3611
IM V19
IM 3631
IM B7
IM 1061
IM B8
IM 1071
Foot-motor:
Code I
Code II
*)
IM 3061
*)
IM 3071
Flange-mounted motor,
large flange with
clearance fixing holes.
Code I
Code II
Flange-mounted motor,
small flange with
tapped fixing holes.

May 26, 2015 | Slide 123
*)
IM 3651
*)
IM 3661
*)
IM 3671
International Standards
IM Mounting Arrangements
IEC 60034- 7
Example of designations acc. to Code II
Designation for
International mounting
IM 1
00
Type of construction, foot-mounted

motor with two bearing end shields
Mounting arrangement, horizontal
mounting with feet downwards etc.
External shaft extension, one
cylindrical shaft extension etc.
IEC 34-7 specifies two ways of stating how a motor is mounted.
Code I covers only motors with bearing end shields and one shaft extension.
Code II is a general code.
-
Mounting arrangement is very important to manufacturer as there might have some

special consideration required especially for vertical mounted motors (eg: V3, V6,
V1.)
Special end shield or seals is required for those shaft upwards where water/liquid are
expected to go down along the shaft.

May 26, 2015 | Slide 124
Motor Dimensions and Powers

IEC 60034-7
Acc. to Cenelec Harmonization Document (HD 231)

May 26, 2015 | Slide 125
Noise
IEC 60034-9

May 26, 2015 | Slide 126
ABBs motors have a low noise level
Average test values are presented in respective product

catalogues
Guaranteed noise data can be supplied on request
Noise level is given as mean sound pressure level at full load and
1 m distance
Vibration
IEC 60034-14
Limits of maximum vibration magnitude in displacement, velocity and acceleration (r.m.s.) for shaft height H
Grade A applies to machines with no special vibration requirements.
Grade B applies to machines with special vibration requirements. Rigid mounting is not considered acceptable for
machines with shaft heights less than 132 mm.
The interface frequencies for displacement/velocity and velocity/acceleration are 10 Hz and 250 Hz respectively.
Vibration
Large
Most
AC motor had to be install at rigid mounting
coupling can take grade A vibration easily.
Standard
Grade A is the
standard grade
used by ABB
May 26, 2015 | Slide 127
affect coupling and foundation design
ABB Large AC motor grade A vibration, grade B is an option.
Basic IEC Standard

Starting And Re-Starting
During starting, rotor is in 0 speed.
High starting current drawn by motor, high magnetic flux generated.
Additional stress on insulation, aging on insulation.
ABB standard design life time 20 years with 1000 start per year
ABB BU Motors and Generators May 26, 2015 | Slide 128
Basic IEC Standard

Starting and Re-Starting
High starting current drawn by motor during starting
Network voltage will reduce depend on short circuit capacity
With lower voltage, lower torque generated, motor maybe unable to start
Common industry requirement is motor had to start at 80% Un
Load curve is needed to confirm motor starting
ABB standard, motor torque need to be at least 10~15% higher than load torque
Basic IEC Standard

Starting and Re-Starting
3/2 start or 2/1 start is often

required.
Cold start -> motor at

ambient temp
Hot start -> motor at

operating temp
Higher inertia lead to longer

starting time, higher motor
temperature
With load curve and inertia,

3/2 or 2/1 start can be
confirm.
Basic IEC Standard

IEC 60079 Explosive atmospheres
Standars
EN 60079-0
IEC 600790
General Rules for all Ex Motors
EN 60079-2
IEC 600792
Pressurised
p
EN 60079-1
IEC 600791
Flame Proof
d
EN 60079-7
IEC 600797
Increased Safety
e
EN 60079-15
IEC 6007915
Non Sparking
n
Zones
ZONE 1
ZONE 2
Motor category (ATEX only)

Category 2
M
G
May 26, 2015 | Slide 131
Category 3
PG Large AC Motors
Product portfolio
ABB Group
May 26, 2015 | Slide 132
Cast iron motors
Modular induction motors
Flameproof motors
Slip-ring motors
Synchronous motors
LV induction motors using

form wound coils
PG Large AC Motor product offering

HV induction and synchronous motors
Output power
HV induction motors
Synchronous motors
140 kW 23 MW
1 65 MW
ABB Group
May 26, 2015 | Slide 133

Rib cooled motors
Process performance motor
Standard high voltage motor
Based on proven platform
For serial OEMs with short delivery time
ABB Group
May 26, 2015 | Slide 134
Power: 110 750 kW

Frame sizes: 315 450

Rib cooled motors
Engineered rib cooled motor NXR
Power 100 900 kW
Frame sizes: 355 to 400
New platform for HV rib cooled motors
High efficiency levels, low noise levels
Fixed speed and safe area use
Engineered rib cooled motor HXR
ABB Group
May 26, 2015 | Slide 135
Power 100 2,250 kW
Frame sizes: 355 to 560
High efficiency levels, low noise levels
Fixed speed, variable speed and

hazardous are use

Modular induction motors
Built from the basic design by using modular construction
Complete range of enclosures and cooling arrangements
Optimal weight to power ratio
ABB Group
May 26, 2015 | Slide 136
Power: 140 23,000 kW

Optimized electrical design
Vacuum pressure impregnated stator winding
Reliable and rugged heavy-duty construction
Low vibration and noise levels
Fit for frequency converter supply
Designed for tough ambient conditions
Easy installation and maintenance
Wide range of accessories
Wide range of applications including compressors, pumps,

fans, blowers, conveyors, mills, crushers, refiners and ship
thrusters

Flameproof motors Ex d
Motor intended for explosive

atmosphere
Protection category acc. to EN/IEC
Flameproof Ex d, Ex de
Totally enclosed, fan cooled

Cooling methods: IC411 and IC511
Both cast iron and welded steel frame

available
Certified according to ATEX Directives,

IEC, EN and NEMA standards and all
major local requirements
Suitable for variable speed drives
ABB Group
May 26, 2015 | Slide 137
Power: 160 8,000 kW


Slip-ring motors
Slip ring unit located separately at the

end of the motor to allow easy
maintenance
Can be equipped with permanent

contact brushes
Suitable for variable speed drives or

with a brush lifting device for continuous
running
ABB Group
May 26, 2015 | Slide 138
Power: 300 18,000 kW


Synchronous motors
ABB synchronous motor modular product

platforms cover:
ABB Group
May 26, 2015 | Slide 139
From small to large power:

1 - 65 MW
1 300 - 87 000 HP
From slow to full speed: 20 - 2000 rpm (also
2 pole available)
From small to large size:
Shaft height 0710 - 2500 mm
From medium to very high voltages:
1 - 60 kV
Endshield and pedestal mounted, horizontal
and vertical design
All main cooling types
Motor design for hazardous environment
according to main Ex standards
All main DOL starting methods and VSD
technology supported

Motorformer
ABB Group
May 26, 2015 | Slide 140
Motorformer (Very High Voltage motors)

with a new stator technology, based on
patented and well-known high voltage
cable winding concept
Lower operating costs and increased

utilization of reactive power due to
eliminating the power transformer
system
Fewer components for savings in

servicing, maintenance and spare parts
Complete range of enclosures and

cooling arrangements
Low weight to power ratio

May 26, 2015 | Slide 141
Agenda
Chng trnh
Time - Thi gian
08:30 09:00
9:00 09:15
9:15 10:45
Content - Ni dung
Ta nh REE
10:45 11:00
11:00 12:00
11:45 12:00
13:00 13:30
13:30 15:15
Break - GIi lao

Lunch - Buffet tra
15:15 15:30
15:30 16:30
Break - Gii lao

Dch v k thut
16:30 17:00
ABB
May 26, 2015
| Slide 142
BU Drives and Controls, January 2015
Drives, PLC and automation products

for all needs
ABB
May 26, 2015
Slide 143
ABB BU Drives and Controls

Products
Low voltage AC and DC drives
Micro drives 0.18 to 4 kW
Machinery drives 0.18 to 560 kW
General purpose drives 0.75 to 355 kW
Motion control products 1 to 33 kW
Industrial drives
Medium voltage AC drives
Low voltage AC 0.55 to 5600 kW
General purpose drives 0.25 to 7 MW
Low voltage DC 7.5 kW to 4.8 MW
Special purpose drives 2 to 100 MW
Industrial specific drives 0.37 to 400 kW PLC and Automation products

AC500-eCo, AC500
Drives for HVAC
AC500-S, AC500-XC
Drives for water
S500 Remote I/O
CP600 HMI
ABB
May 26, 2015
Slide 144
BU Drives and Controls

Markets served
ABB
May 26, 2015
Slide 145
HVAC
Food industry
Beverage industry
Marine
Pulp & Paper
Metals industry
Mining
Power generation
Cement
Chemicals
Oil upstream
Plastics
Material handling
Textile
Water and waste water
Motion
Low voltage AC drives

Products
ABB
May 26, 2015
Slide 146
ABB general purpose drives

ACS550, 0.75 to 355 kW
ABB
May 26, 2015
Slide 147
From 200 to 480 V
For pumps, fans, and constant torque applications
IP21 and IP54 enclosures
Vector control
Assistant control panel
EMC filter (C2)
Modbus RS-485
Swinging choke for superior harmonic reduction
Options
Basic control panel
Fieldbus adapters, panel mounting kits, relay

output extension module
Output chokes
Brake units and choppers
FlashDrop tool
ABB machinery drives

ACS850-04, 1.1 to 500 kW
ABB
May 26, 2015
Slide 148
From 380 to 500 V
IP20
Fast, cost effective cabinet installation and

integration
Compact size and side-by-side mounting
Wide range of options and extensive standard

inputs and outputs
Safe Torque Off (STO)
Removable memory unit
Drive-to-drive link for master-follower application
Energy optimizer and energy saving calculator
Options
Control panel
Crane control software
Various power and IO options
ABB industrial drives

ACS880 series 0.55 to 5600 kW
ACS880 single drives
ACS880 multidrive
ACS880 drive modules

ABB
May 26, 2015
Slide 149
Single drives
ACS880 0.55 to 3200 kW
ABB
May 26, 2015
Slide 150
Wall-mounted drives, ACS880-01
Cabinet-built drives, ACS880-07
Voltage range from 208 to 690 V
Built on ABBs all-compatible drives architecture:
Intuitive control panel and PC tool
Enhanced direct torque control (DTC) for

precise open and closed loop control
Built-in safety features
Communication with all major automation

networks
Removable memory unit for easy drive

commissioning and replacement
Energy optimizer and energy efficiency

information
Application control programs and drive

application programming with IEC 61131-3
programming
Drive modules
ACS880 0.55 to 3200 kW
Designed for system integrators and OEMs who

integrate drive modules into their own systems or
subsystems.
Built on ABBs all-compatible drives architecture
Air-cooled multidrive modules:
ABB
May 26, 2015
Slide 151
Inverter modules, 380 to 690 V
IGBT supply modules, 150 to 630 kVA
Diode supply modules (DSU), 55 to 5445 kVA
Brake choppers and resistors
Air-cooled single drive modules:
ACS880-04, IP20
ACS880-01, IP20 +P940
LV AC drive modules engineering support -site
Multidrives
ACS880 1.5 to 5600 kW
ABB
May 26, 2015
Slide 152
Voltage range from 380 to 690 V
Built on ABBs all-compatible drives architecture
Air-cooled multidrives with:
Inverter units, 380 to 690 V
IGBT supply units, 380 to 500 V
Diode supply units (DSU), 55 to 5500 kVA
Common DC busbar with single power line

connection
Compact design for easy cabinet assembly and

maintenance
Fast connectors for motor cables in the bottom

part of the cabinet
Shared energy and motor-to-motor braking

without braking chopper or regenerative supply
unit
Common braking resourced to several drives
ABB industry-specific drives for HVAC

ACH550, 0.75 to 355 kW
ABB
May 26, 2015
Slide 153
From 208 to 480 V
Full motor current up to 50C
IP21 or IP54
Assistant control panel
Specific application macros
Embedded BACnet, Modbus, N2 and FLN

protocols
Swinging choke for superior harmonic

reduction
EMC filter (C2)
Options
Fieldbus adapters, panel mounting kits, relay

output extension module
Output chokes
FlashDrop
ABB industry-specific drives for water and wastewater

ACQ810-04 , 1.1 to 400 kW
ABB
May 26, 2015
Slide 154
T 380 n 480 V
IP20
Tailor-made pump control functions for single

and multi-pump systems
Assistants for pump system start-up,

maintenance and diagnostics
Energy optimizer and energy efficiency

calculator
Side-by-side mounting
Coated boards
Options
I/O extensions
Fieldbus adapter modules
Harmonics filters
EMC (C2) filters
ABB application control programs
ABB
May 26, 2015
Centrifuge and decanter control program for effective separation of solids

from liquids and co-ordinated speed difference control
Crane control program
Master/follower control program for load sharing between mechanically

connected motors
Multiblock control program for versatile adaptive programming
Motion control program for positioning and synchronising in machinery

applications
PMSM control program Permanent magnet motor control for high torque and
low-speed applications
Pump control program
Rod pump control program and PCP/ESP pump control program for the oil
industry
Spinning and traverse control programs for high-quality yarn production
Winch control program for mooring and anchor handling
Winder control program for precise tension
Slide 155
PC tools, remote monitoring

options and fieldbus
adapters
ABB
May 26, 2015
Slide 156
Drive PC tools
Engineering tools
DriveSize and MCSize - dimensioning drives and
motors
Integration tools
DriveOPC Integrating ACS800 with OPC
Programming tools
DriveSPC - programming of ACSM1, ACS850
DriveAP - adaptive programming of ACS800
ABB
May 26, 2015
Start-up and maintenance tools

Drive composer All-compatible drives portfolio
including ACS880, ACS580 drives
DriveStudio ACSM1, ACS850 drives
DriveWindow - ACS800 drives
DriveAnalyzer ACS800 drives
DriveWindow Light standard drives
DrivePM creating FlashDrop parameter sets
DriveConfig kit for ACS55
DriveBrowser - fieldbus based tool connected to
Ethernet network
Slide 157
Drive PC tools
Tools for calculating energy savings
ABB
May 26, 2015
Slide 158
FanSave
for comparing energy consumption
between different fan control methods
PumpSave
for comparing energy consumption
between different pump control methods
Remote monitoring tools

SREA-01, Ethernet adapter
Main features
Remote monitoring using a web browser
Remote access to drive parameters
Local trending, send logs by e-mail
Alarming by e-mail and SMS

Connectivity
Local Ethernet (Internet connectivity via external firewall)
EIA-232 for GSM, GPRS, 3G or analog modem
EIA-232, EIA-485 or Ethernet for drive connection
Connection to the drive by Modbus (panel port, embedded Modbus or a

Modbus adapter)
Possibility to connect up to 10 drives

Drive compatibility
ACS310, ACS355, ACS550, ACH550, ACQ810, ACS850, ACSM1
Limited to ACS800-01 (standard control program)

ABB
May 26, 2015
Slide 159
Remote monitoring tools

NETA-01, Ethernet adapter
Main features
Remote monitoring using a web browser
Remote access to drive parameters
E-mail alarms and reports
Modbus/TCP for monitoring and control
Response time ~100 ms

Connectivity
Local network (Ethernet)
DDCS for drive connection
Possibility to connect up to 9 drives

Drive compatibility
ACS800 (with DDCS option modules)
ABB
May 26, 2015
Slide 160
Agenda
Chng trnh
Time - Thi gian
08:30 09:00
9:00 09:15
9:15 10:45
Content - Ni dung
Ta nh REE
10:45 11:00
11:00 12:00
11:45 12:00
13:00 13:30
13:30 15:15
Break - GIi lao

Lunch - Buffet tra
15:15 15:30
15:30 16:30
Break - Gii lao

Dch v k thut
16:30 17:00
ABB
May 26, 2015
| Slide 162
Chee-Seong Chiam
27th May 2015
BU Motors & Generators

Dimensioning Tool MotSize/ DriveSize
ABB BU LV Motors
May 26, 2015 | Slide 163
Background
RollDIM
Rose
Harmon16
CraneDIM
Softsize
One
Dimensioning
Tool
Etc.
ACDDIM
PC-Cat
ABB BU LV Motors
May 26, 2015 | Slide 164
Approximately 12 different tools for AC drive dimensioning
Requirement for a user friendly and reliable tool
Standardize the rules for dimensioning and insure that

results were accurate
Software based on the Windows environment
Program
User interface
- Project Information
- Selected Units
MotSize
Project
Database
Hazardous
MotSize
Direct
On Line
area
Motors
motors
DriveSize
ACS 550
Safe area
motors
ACS 800
ACS 1000
Rose
Trafo
Product Specific
Dimensioning Rules
ABB BU LV Motors
May 26, 2015 | Slide 165
ACS 800
Catalogue
ACS 1000
Catalogue
ACS 550
Catalogue
Motor
Catalogue
Trafo
Catalogue
Product Databases
Available Motor Types in Program

Standard Motors
Aluminum
Cast Iron
Break motors
Ex Motors
1. Aluminium
- ExnA
2. Cast Iron
- ExnA
- Exd/de
- Exe
- DIP/ExtD
ABB BU LV Motors
May 26, 2015 | Slide 166
Marine Motors
Aluminum
Cast Iron
General Program Features
ABB BU LV Motors
May 26, 2015 | Slide 167
Ambient temperature
Altitude
Supply network data
Load type and duty cycle
Motor temperature rise
Both imperial and metric units
Results in numerical and graphical form
Print outs
MotSize Main Screen Parameters

Select list of motors
According to catalogue
Standard
Brake
Basic
Highoutput
Not specified
Y
D
Up to 55C, EEx 50 C, EEx e

40 C
60C 80C : for information
Up to 4000 m
Load type
What ever
B for 80K
F for 105 K
ABB BU LV Motors
May 26, 2015 | Slide 168
Aluminium
Cast iron
List according to Motor type :

M2AA-M2BA-M3AA-M3BPM3JP - M3KP etc.
EEx n T3 EEx e EEx d / de
S1 : Continue duty
S2 : 10 - 30 - 60
S3 / S6 : 15%-25%-40%60%
S4 : Int. duty : cycle/h
Power
restamping
General
Performance
Process
Performance
Marine motors
Hazardous
Areas
Selection Modes
There are 4 different way of choosing a motor:
ABB BU LV Motors
May 26, 2015 | Slide 169
1.
Guided selection
2.
Advanced selection
3.
Catalogue guided selection
4.
Catalogue advanced selection
Starting MotSize (For Direct On Line Start Motors)

Double click on
MotSize shortcut icon
in desktop or Windows
Program list
MotSize
launching
screen
ABB BU LV Motors
May 26, 2015 | Slide 170
Starting MotSize
Fill in the motor range and project information.

ABB BU LV Motors
May 26, 2015 | Slide 171
Supply Ratings
Select voltage
ABB BU LV Motors
May 26, 2015 | Slide 172
frequency
Guided Selection
Example: Choosing an IE2,16kW, 4-pole, cast iron Process Performance motor
To start dimensioning
you have to click one of
these icons
Or press Ctrl+D
Or press Tools, make
dimensions
ABB BU LV Motors
May 26, 2015 | Slide 173
Guided Selection
ABB BU LV Motors
May 26, 2015 | Slide 174
Guided selection shows all available standard motors

160 kW 4-poles.
Now you can select the type you want
Advanced Selection
This is like guided selection BUT you have to select motor type and family
ABB BU LV Motors
May 26, 2015 | Slide 175
Catalogue Guided Selection
You can limit your selection by choosing just a certain power

or the whole catalogue range
ABB BU LV Motors
May 26, 2015 | Slide 176
Catalogue Guided Selection
Table shows all motors selectable from catalogue between 11

- 20 kW ->
You have to pick the ones you need
ABB BU LV Motors
May 26, 2015 | Slide 177
Catalogue Advanced Selection

This is like guided selection BUT you have to select motor type, family and power range.
ABB BU LV Motors
May 26, 2015 | Slide 178
Catalogue Advanced Selection
ABB BU LV Motors
May 26, 2015 | Slide 179
Exercise 1
ABB BU LV Motors
May 26, 2015 | Slide 180
Kindly advise a DOL motor that meet requirements below:
IE2 aluminium M3AA frame size 200 motor
Power 30 kW, 415VD, 50Hz, 2-pole, IM B35
Ambient temperature 50C, altitude 1000m
Aluminium frame, IP 56, according to IEC
Temperature Class B
Restamp the motor to 27 kW
Inform the Efficiency level and Power Factor at 100% ,

75% and 50% of load
Generate the datasheet in Finnish language
Starting MotSize (For Direct On Line Start Motors)

Double click on
MotSize shortcut icon
in desktop or Windows
Program list
MotSize
launching
screen
ABB BU LV Motors
May 26, 2015 | Slide 181
Exercise 1. Project Information
ABB BU LV Motors
May 26, 2015 | Slide 182
Exercise 1. Main Screen Network data
Choose network:
Voltage 415V and
Frequency 50Hz
ABB BU LV Motors
May 26, 2015 | Slide 183
Exercise 1. Motor Selection
Choose:
Range
Temperature rise
Poles
Load
IP class
Mounting
ABB BU LV Motors
May 26, 2015 | Slide 184
To start dimensioning
you have to click one of
these icons
Or press Ctrl+D
Or press Tools, make
dimensions
Exercise 1. Motor Selection
Choose the motor

you want
ABB BU LV Motors
May 26, 2015 | Slide 185
Exercise 1. Restamp the motor
Restamping can be done by entering new power here or by selecting the Run button
ABB BU LV Motors
May 26, 2015 | Slide 186
Exercise 1. Running Performance
ABB BU LV Motors
May 26, 2015 | Slide 187
Exercise 1. Results
Click on the buttom Results to see the values of Efficiency level and
Power Factor at 100% , 75% and 50% of load.
ABB BU LV Motors
May 26, 2015 | Slide 188
Exercise 1: Datasheet
ABB BU LV Motors
May 26, 2015 | Slide 189
Exercise 1: Datasheet
ABB BU LV Motors
May 26, 2015 | Slide 190
Exercise 2
ABB BU LV Motors
May 26, 2015 | Slide 191
Kindly advise a DOL motor that meet requirements below:
IE2 cast iron motor
Group II, Zone 1, IIC, T4
Power 90 kW, 380VD, 50Hz, 4-pole, IM V1
Aluminium frame, IP 56, according to IEC
Temperature Class B
Restamp the motor to 85 kW
Inform the Efficiency level and Power Factor at 100% ,

75% and 50% of load
Generate the datasheet in English language
Exercise 2. Project Information
ABB BU LV Motors
May 26, 2015 | Slide 192
Exercise 2. Results
ABB BU LV Motors
May 26, 2015 | Slide 193
Exercise 3
ABB BU LV Motors
May 26, 2015 | Slide 194
Select the right motor:
Cast Iron
Power 160 kW, 690V, 50Hz,IM B5
Load type constant torque and constant power
Speed range 500-1000-1500rpm
Overload 120% for 25s at every 600s
IP 55, according to IEC
Temperature Class B
Cooling IC416
Exercise 3: Starting DriveSize (For VSD Start Motors)

Double click on
DriveSize shortcut
icon in desktop or
Windows Program list
DriveSize
launching
screen
ABB BU LV Motors
May 26, 2015 | Slide 195
Exercise 3: DriveSize Main Screen Parameters

Load type:
constant torque/
constant power/
constant torque
and power
To be filled up:
Speed range/
power/ overload
and period
Network
supply, type of
drive and
motor
selections
ABB BU LV Motors
May 26, 2015 | Slide 196
Overload type:
Simple cyclic/
multiform cyclic/
one time at start
Choose:
Motor type/
Temperature rise
IP class
Mounting
Exercise 3: Key in the voltage and frequency
First, select the

network supply
page
ABB BU LV Motors
May 26, 2015 | Slide 197
Next, input the

voltage and
frequency
Exercise 3: VSD Motor Selection
Input all the

data in the
columns
Select the
motor selection
page
ABB BU LV Motors
May 26, 2015 | Slide 198
Press CTR+A once all the data have been inputted.
Exercise 3: Selected Motor
Drive selected: ACS800-02-0260-7

Motor selected: M3BP355SMB6
ABB BU LV Motors
May 26, 2015 | Slide 199
Agenda
Chng trnh
Time - Thi gian
08:30 09:00
9:00 09:15
9:15 10:45
Content - Ni dung
Ta nh REE
10:45 11:00
11:00 12:00
11:45 12:00
13:00 13:30
13:30 15:15
Break - GIi lao

Lunch - Buffet tra
15:15 15:30
15:30 16:30
Break - Gii lao

Dch v k thut
16:30 17:00
ABB
May 26, 2015
| Slide 201
NEMA and MPT Products

ABB
July 19, 2012 | Slide 202
ABB and Baldor

Integration
ABB acquired Baldor Electric Company, a North American
leader in premium efficient industrial electric motors and
mechanical power transmission products on January 27,
2011
This combination creates the worlds largest provider of
industrial electric motors
This combination provides ABB with a market leading family
of enclosed gearing, mounted bearings and power
transmission components
ABB
May 26, 2015
Slide 203
About Baldor
Baldor Electric Company was founded in 1920 to

build a better motor
Only industrial products (no residential or automotive)
Leading customer preference in North America for
industrial electric motors with Baldor*Reliance
brand
Market leading line of mechanical power transmission
product with Dodge brand
Very broad and diverse customer base
more than 175 end markets
more than 10,000 customers worldwide
Award-winning, union-free manufacturing facilities
Acquired Reliance and Dodge brands in 2007,
doubling the size of the company
7,000 + employees globally
Products sold in over 70 countries
ABB
May 26, 2015
Slide 204
About Baldor
Region Sales Support and Application Engineering
Baldor team
Baldor team
Vasteras, Sweden
Bristol, England
Baldor team
Cologne, Germany
Baldor team
Milan, Italy
Baldor team
Dubai, UAE
Baldor team
Baldor US Team
Shanghai, China
Baldor team
Pune, India
Baldor team
Baldor team
Santiago, Chile
Singapore
Baldor team
Alrode, South Africa
ABB
May 26, 2015
Slide 205
Baldor team
Seven Hills, Australia
Dodge mechanical products

complement motors and drives
Motors, drives and mechanical power transmission

products can be used together in many applications
Inbound
Power
Drives
ABB
May 26, 2015
Slide 206
Motors
Mechanical Power
Transmission
Products
Motion driven
equipment
Example
ABB offering for Air Handling
ABB Drives
ABB IEC Motors
or
Dodge Couplings
Grid-Lign Coupling 6,000 + kW

at 1450 RPM
Dodge Mounted
Bearing Units
Sleevoil
Hydrodynamic
Bearing Up to 14
/ 350 mm
HFO
Oil Lubricated
Spherical Bearing
75 240 mm
ISN
Grease
Lubricated
Spherical Bearing
30 140 mm
SC
Grease
Lubricated Ball
Bearing 17 85
mm
Baldor*Reliance
NEMA Motors
Gear Coupling 18,000 kW at

1450 RPM
ABB
May 26, 2015
Slide 207
NEMA and MPT

Product portfolio BU M&G
BaldorReliance NEMA Motors
ABB
May 26, 2015
Slide 208
Dodge Mechanical Power

Transmission Products
NEMA motor family from Baldor
AC Motors
More than 175 end markets
Super-E premium efficient family
Single phase
Specialty
Adjustable speed
Above NEMA frame
DC Motors
More than 175 end markets
Fractional HP PM and Wound Field
Round Body
Laminated Frame
ABB
May 26, 2015
Slide 209
MPT products from Baldor
Mounted bearings
Enclosed gearing
Couplings
Sheaves
Bushings
ABB
May 26, 2015
Slide 210
Dodge enclosed gearing products
Torque-Arm and TAII Shaft Mount
MagnaGear XTR
ABB
May 26, 2015
Slide 211
Quantis Helical and Bevel-helical Gearmotors
Motorized Torque Arm
Controlled Start Transmission (CST)
Dodge mounted bearings
Mounted Ball Bearings

12 mm to 85 mm bore ( to 3 )
Additional secondary subject
Pillow block, flange units and take-ups
Set screw, clamp collar, adapter and eccentric mount
Cast iron, polymer and stainless steel
All industries
Mounted Roller Bearings
30 mm to 400 mm bore (1 to 15 )
Mounted tapered and mounted spherical roller
Pillow block, flange units and take-ups
Set screw, adapter and direct mount
Mining, aggregate & cement, air handling and power
generation
Mounted Plain (or Sleeve) Bearings
80 mm to 350 mm (1-7/16 to 14)
Oil film hydrodynamic bearing
Air, water and oil cooled
High speeds, hot shafts
Industrial fans used in power generation, petroleum
ABB
May 26, 2015
Slide 212
Dodge couplings
Elastomeric and metallic coupling families
ABB
May 26, 2015
Slide 213
Dodge couplings
Elastomeric couplings
Para-Flex
Para-Flex Couplings
employ a molded, nonlubricated elastomeric
flexing member loaded in
shear; ATEX certified
Industry - Steel, Copper, Paper,

Petro-chemical, Food, WW,
Transportation
Applications Pumps;
Compressors; Fans;
Conveyors, motors, engines,
and turbines
ABB
May 26, 2015
Slide 214
D-Flex
D-Flex Couplings employ a

molded, non-lubricated
elastomeric flexing sleeve
loaded in shear; ATEX
certified

Transportation
Applications Pumps;
Compressors; Fans;
and turbines
Poly-Disc
Poly-Disc Couplings are a pin

type coupling using a molded
polyurethane disc

Transportation
Applications Pumps;
Compressors; Fans;
and turbines
Dodge couplings
Metallic couplings
ABB
May 26, 2015
New Disc Coupling
Grid-Lign
Gear
Tapered grid style

Hubs, grids, and
covers
Power dense and

capable of transmitting
high torque at high
speeds while still
remaining inherently
well balanced
Industry leading torque

and misalignment
capabilities for longer life
and improved reliability.
Non-lubricated disc design
increases productivity.
Industry - Steel, Copper,

Paper, Petrochemical, Food, WW,
Transportation
Applications Pumps;
Compressors; Fans;
Conveyors, motors,
engines, and turbines
Industry - Steel, Copper,

Paper, Petrochemical, Food, WW,
Transportation
Applications Pumps;
Compressors; Fans;
Conveyors, motors,
engines, and turbines
Industry Chemical, Oil,

and Gas; Pulp &
Paper.
Applications Pumps;
Compressors; Fans;
motors, engines, and
turbines
Slide 215
Dodge PT Components
Mechanical drive components
Sheaves and Bushings
V-Belt & High Torque Synchronous Belt
Drives-HTR and HTRC
Taper-lock or QD bushing availability
Industries-Air and Material Handling
ABB
May 26, 2015
Slide 216
Key industries for mechanical power transmission

Food/Beverage
ABB
May 26, 2015
Pharmaceutical
Mining
Metals
PowerGen
Water/Waste Water
Pulp & Paper
Forest Products
Petroleum
Chemical
Aggregate
Cement
Unit/Bag Handling
Air Handling
Slide 217
ABB
May 26, 2015
Slide 218
NEMA vs. IEC Motors

May 26, 2015 | Slide 219
General Overview
Fundamental motor operation is the same
Both are induction motors
National Electrical Manufacturers Association (NEMA)
Primary standards in the United States
Prevalent in Canada, Mexico as well
International Electrotechnical Commission (IEC)
Most widely adopted standards worldwide
IEC defined requirements issued as Directives by the EU

May 26, 2015 | Slide 220
67 member countries, including the US
International standards frequently incorporated into local country

specifications
Metric vs. IEC there is a difference
Merging of Standards
Harmonizing of standards required to create a truly global marketplace
IEC enclosure and ventilation codes (IC) are now in the NEMA MG standards
NEC incorporates IEC hazardous area zone classifications
Restriction of Hazardous Substances (RoHS) is an EU directive
Does not currently apply to motors
Efficiency calculations
IEC used to assume a fixed value for stray losses, NEMA measures actual values.
With the new standard IEC use the same method as NEMA
US participation in standards writing is declining
Reasonable to expect further infusion of IEC specifications

May 26, 2015 | Slide 221
Aspects for Comparison

May 26, 2015 | Slide 222
Power ratings
Voltage, frequency & speed
Service factor
Insulation classes
Efficiency
Altitude
Ambient
Cooling codes
Ingress protection
Mounting positions
Terminal boxes
Frame size designations
Output characteristics
Dimensions
Hazardous areas
Power Ratings
NEMA motors rated in horsepower (HP)
1 HP = power to lift 33,000 pounds 1 foot in 1 minute
IEC uses kilowatts (kW)
HP x 0.746 = kW or kW/0.746 = HP
Both NEMA and IEC assign specific power ratings to certain frame
sizes according to speed
In general, output power ratings and frame sizes are comparable

May 26, 2015 | Slide 223
There are some exceptions, and in these cases there can be frame
size differences to be taken into consideration
Voltage, Frequency & Speed
Common voltages around the world

Voltage & frequency combinations
* Voltages occasionally seen at 60 Hz
50 Hz
220
240
380*
400*
415
500
600
690
60 Hz
230
---
440
460
480
575
660
---
---
Maximum voltage variation: NEMA 10%; IEC 5%
Maximum frequency variation: NEMA 5%; IEC 2%
Base speeds based on number of poles

Speed (rpm)

May 26, 2015 | Slide 224
Poles
10
12
50 Hz
3000
1500
1000
750
600
500
60 Hz
3600
1800
1200
900
720
600
Service Factor
Definition: Permissible amount of overload a motor will handle within defined

temperature limits without overheating
Motor may be loaded according to the value of rated power times service factor
Primary uses
Compensate for inaccuracy in predicting system power needs
Lengthen insulation life by lowering winding temperature at rated load
Handle intermittent overloads or unbalanced supply voltages

May 26, 2015 | Slide 225
Service Factor
14.37 APPLICATION OF ALTERNATING-CURRENT MOTORS WITH SERVICE FACTORS

14.37.1 General
A general-purpose alternating-current motor or any alternating-current motor having a service factor in
accordance with 12.52 is suitable for continuous operation at rated load under the usual service conditions
given in 14.2. When the voltage and frequency are maintained at the value specified on the nameplate, the
motor may be overloaded up to the horsepower obtained by multiplying the rated horsepower by the
service factor shown on the nameplate.
When the motor is operated at any service factor greater than 1, it may have efficiency, power factor, and
speed different from those at rated load, but the locked-rotor torque and current and breakdown torque will
remain unchanged.
A motor operating continuously at any service factor greater than 1 will have a reduced life expectancy
compared to operating at its rated nameplate horsepower. Insulation life and bearing life are reduced by the
service factor load.
NEMA Standards Publication MG 1-2006 Revision 1
Part 14, Page 12

May 26, 2015 | Slide 226
Service factor is not recognized by IEC
Motors are designed to deliver rated power for an

average lifetime
Size the motor to the application requirements
International Cooling Codes
IC codes are now included in NEMA enclosure type definitions

1.26.2 Totally Enclosed Fan-Cooled Machine
A totally enclosed fan-cooled machine is a frame-surface cooled totally enclosed machine equipped
for self exterior cooling by means of a fan or fans integral with the machine but external to the
enclosing parts.
1.26.3 Totally Enclosed Fan-Cooled Guarded Machine (IC411)
A totally-enclosed fan-cooled guarded machine is a totally-enclosed fan-cooled machine in which all
openings giving direct access to the fan are limited in size by the design of the structural parts or by
screens, grilles, expanded metal, etc., to prevent accidental contact with the fan. Such openings
shall not permit the passage of a cylindrical rod 0.75 inch diameter, and a probe such as that shown
in Figure 1-1 shall not contact the blades, spokes, or other irregular surfaces of the fan.
IEC specifies detail using letter

& number codes for definition
IC 410 motor w/o fan
IC 411 TEFC
Publication:
IC 416 TEBC
MG 12006 Revision 1
2007
IC 418 TEAO
part 1, page 17 & 18
IC 01 ODP
NEMA Standards

May 26, 2015 | Slide 227
Ingress Protection
Code Definitions
Protection Against Solid Bodies
Protection Against Liquid
No Protection
No Protection
Objects > 50 mm
Vertically dripping water
Objects > 12 mm
75o to 90o dripping water
Objects > 2.5 mm
Sprayed water
Objects > 1 mm
Splashed water
Dust protected
Water jets
Dust-tight
Heavy seas
-----
Effects of immersion
-----
Indefinite immersion
Comparative Examples
NEMA Type 1 = IP 10
NEMA Type 3 = IP 14
NEMA Type 3R = IP 54
May 26, 2015 | Slide 228
NEMA Type 4/4X = IP 55

NEMA Type 12 = IP 52
NEMA Type 13 = IP 54
Mounting Positions
NEMA Definitions
4.3 MOTOR MOUNTING AND TERMINAL
HOUSING LOCATION
The motor mounting and location of terminal
housing shall be as shown in assembly symbol
F-1 of Figure 4-6. Where other motor mountings
and terminal housing locations are required,
they shall be designated in accordance with the
symbols shown in Figure 4-6.
Assembly symbols F-1, W-2, W-3, W-6, W-8,
and C-2 show the terminal housing in the same
relative location with respect to the mounting
feet and the shaft extension.
All mountings shown may not be available for all
methods of motor construction.
NEMA Standards Publication MG 1-2006 Revision 1
Part 4, Pages 12 & 13

May 26, 2015 | Slide 229
Terminal Boxes
NEMA standard location is on left hand

side facing output shaft (F1)
IEC has no standard, the most common

is on the top (this is ABB standard)
Optional locations on either side

left (F1) or right (F2)
Terminal box can generally be rotated

4 x 90 degrees
Terminal posts make for easy

connection of leads

May 26, 2015 | Slide 230
Optional positions on right hand side

(F2) and on top (F0)
Flying leads require extra space to

connect and contain inside
Frame Size Designations
First two (2) digits of NEMA frame size designation represent four (4) times
the actual shaft height in inches
IEC motors use actual shaft height in millimeters
EX: 11 inch shaft height x 4 = 44_ frame size
EX: 280 mm shaft height = 280 frame
Most frame sizes in either NEMA or IEC have a comparable equivalent in

terms of shaft height
EX: 280 mm/(25.4 mm/in) = 11.02 inches
EX: 11 in x 25.4 mm/in = 279.4 mm
One exception there is a 100 frame IEC motor which has no

comparable NEMA counterpart

May 26, 2015 | Slide 231
[100 mm/(25.4 mm/in)] x 4 = 15.7 inches => NEMA 160 frame?
Frame Size
Designation Comparisons

May 26, 2015 | Slide 232
IEC defines a wider range
56 through 1000 mm shaft heights
No NEMA equivalents for all of them
NEMA technically stops with 440 frame series
Up to 680 frame listed in MG-1 standard
IEC
56
63
71
80
90
100
112
132
160
180
200
225
NEMA
---
42
48
56
140
---
180
210
250
280
320
360
IEC
250
280
315
355
400
450
500
560
630
710
800
900
1000
NEMA
400
440
500
580
680
700
800
---
---
---
---
---
---
Dimensions
Comparisons
IEC measurement labels tend to be more

logically defined
Length
Shaft height
NEMA = D, IEC = H
Shaft diameter

May 26, 2015 | Slide 233
NEMA = C, IEC = L
NEMA = U, IEC = D
IEC dimensions are in mm, NEMA in

inches
Many dimensions are very close to the

same
NEMA output shaft lengths tend to be

longer
Shaft heights, foot spacings, shaft

diameters within 3 or 4 mm

May 26, 2015 | Slide 234
Xuan TranAnh, BU Motors and Generators
Life cycle services for motors,

generators and mechanical power
transmission products
Our service vision
Service will be the key differentiator.

Customers will buy ABB products because of our service,
and not service because of the product.
ABB Group
May 26, 2015 | Slide 236
Our service mission
We aim to understand our customers better than anybody

else.
We believe in passionately serving our customers known
and unknown needs and delivering a service experience
that exceeds their expectations, thereby helping them to
achieve their goals.
ABB Group
May 26, 2015 | Slide 237
Our definition of service
ABB Group
May 26, 2015 | Slide 238
We define service as any activity that adds value to our

customers
We offer service solutions that are our main growth
providers and operational excellence that promotes
ABBs business both in service and in products.
Everything we do, we do safely, sustainably and with
integrity.
Safety
ABB Service solutions for different customers needs

What are the customer needs?
ABB Service solutions
To solve problems
quickly and effectively
to restore its operation
Availability
Technical support
Emergency field service
resources
Spares availability
Onsite and workshop repair
Training
Response time contract
Reliability
Installation and
commissioning
Preventive maintenance
Diagnosis, condition
monitoring
Service contract
To increase process
reliability to avoid
unplanned interruption
in its operation
To optimize operation
to increase
production capacity
ABB Group
May 26, 2015 | Slide 239
Optimization
Engineering and consulting

Spares rationalization
Energy, performance and
reliability appraisal
Upgrade replacement
Life cycle costing
Risk management
Global presence
Global service products, local service centers
Service Center
Service Partner
ABB Group | BU Motors and Generators

August 12, 2012
| Slide 240
A schematic motor life cycle

Traditional situation without service strategy
ABB Group
May 26, 2015 | Slide 241
A schematic motor life cycle

Optimal situation with service strategy in place
ABB Group
May 26, 2015 | Slide 242
Product life cycle management model

Service offering for the different phases
Active
Classic
Obsolete
Guaranteed:
Guaranteed:
When available:
When available:
Selection & dimensioning

Installation & commissioning
Training
Technical support
Maintenance & site service
Spare parts
Repairs & refurbish
Training
Technical support
Spare parts
Repairs & refurbish
Migration & upgrading
Training
Technical support
Spare parts
Repairs & refurbish
Migration & upgrading
Replacement
Technical support
Spare parts
Guaranteed product support
ABB Group
May 26, 2015 | Slide 243
Limited
Limited product support
Replacement
Installation and commissioning
Without a proper installation and commissioning

no amount of maintenance will achieve the
desired performance
Benefits for customers

Electrical work carried out by skilled personnel
only
Safe and controlled start-up methodology
Clearly defined procedures for installation and
commissioning (ex: alignment protocol)
Standard reporting
Reduction in installation and commissioning
time
Improvement in process operation and
efficiency
Warranty protection
Record of parameters
Increase of reliability, availability and safety
ABB Group
May 26, 2015 | Slide 244
Spare-parts
Spare part categories

Operational spare parts
For commissioning and first years of
operation
Recommended spare parts
Extended operational spare parts package
Capital spares
In critical applications
Access to original spare-parts
Expert support in part and capital spares
identification based on motors and generators
condition and criticality
Minimized down-time in case of failure
Ensure motor and generator availability
Single source supplier
On line system Business OnLine
ABB Group
May 26, 2015 | Slide 245
Maintenance
Different approach to maintenance
ABB Group
May 26, 2015 | Slide 246
Reactive maintenance
Failure or abnormal operation
Time based preventive maintenance

Based on manufacturers experience
Condition based predictive maintenance

Maintenance based on actual measurements
Maintenance
Time based preventive maintenance
Investing in preventing of failure, rather than

living with its consequences, such as loss of
production is primary concern for many
businesses.
Successful prevention of failure can make the
difference whether a company manage to retain
its long-term competitiveness

Replaces unplanned disruption with planned
programs so resources can be deployed more
effectively
Proven concept with clear program: L1-L4
Predefined maintenance kits
Scheduled according to planned production
stops
Reduced or eliminated loss of production and
risk of environmental and safety issues
Reduce the overall cost of maintenance
Warranty protection
ABB Group
May 26, 2015 | Slide 247
Maintenance
Condition based predictive maintenance
Maintenance scheduling based on actual condition rather than

time intervals
Requires reliable condition monitoring and diagnostic services

ABB Life Expectancy Analysis Program (ABB LEAP) assesses
the condition of the stator winding insulation in motors and
generators
ABB MACHsenseP offers a comprehensive analysis of
electromagnetic and mechanical faults in motors like rotor
winding defects, installation problems and bearing defects
ABB MACHsense-R (remote service) continuously monitors key
parameters related to the condition of the cage rotor, bearings of
motors and generators, and it can also address temperature
issues.
Site measurements are performed by trained personnel in the

ABB Service Center network
ABB Group
May 26, 2015 | Slide 248
Comfort in knowing condition
ABB creates maintenance plans for motors and generators that

helps our customers to
Minimize unplanned and planned downtime
Extend motors and generators lifetime
Reduce operating risks
On site and workshop repair
The faster a fault can be repaired, the

smaller the consequences.
ABB offers a range of repair services,
warranty or non-warranty, to provide
customers with a choice depending of the
situation and exact financial and operation
needs.
The services include on-site repair by ABB or
its certified partners. If an immediate on-site
repair is not required or not possible a repair
can be carried out a ABBs or its service
partners workshop facilities
ABB Group
May 26, 2015 | Slide 249
Access to technical documentation for ABB

motors and generators
Fast response and high quality of work
through ABBs world wide network of Local
Service Centers
Service contract customized solutions
An efficient way to manage the total life

cycle of motors and generators
Minimizes risk of customer production
One or more services combined to
achieve best possible solution for each
customer

Tailor made services based on product
condition and importance
Customizable for customer to suit
needs, giving cost-effective delivery of a
range of important benefits, coordinated
under one single contract
ABB Group
May 26, 2015 | Slide 250
Training
Service provides trainings to ABBs

customers and end users
General motor and generator
awareness
Maintenance and service
Training can be tailored to suit customers
needs
ABB Group
May 26, 2015 | Slide 251
Employee confidence and motivation

Employee competence in maintenance and
first-line trouble shooting
Competent employees reduces risk of downtime through the ability to interpret alarm
warnings ands undertake appropriate actions
to avoid failures
Gives ability to employees personal to
interact with expert technical support
Replacement
When motors and generators are in limited phases, parts

might not be available anymore or repair cannot be done at
reasonable costs, replacement is the only solution
New standard motors/generators with adaptations
New standard motor/generator with specific electrical and/or

mechanical design (e.g.: foot print)
Upgrading or rebuilding of old motors/generators

Reduction in life cycle costs
Increase of reliability, availability and safety
Selection based on energy calculations possible
Access to latest technology
Expert support in selecting and designing replacement
Access to original drawing and specification for ABB motors

and generators
ABB Group
May 26, 2015 | Slide 252
Technical support and Emergency field service

resources
Technical support through world wide

network of service centers
Fast and competent
Escalation to world leading

experts
Field engineers available on call out
Selection of guaranteed on-site

response time
Quick identification of the problem
Direct service actions to prevent failure

and minimize the consequences
To help minimize your downtime and

bring the motors/generators back on
line
Possibility to optimize in house

maintenance staff.
ABB Group
May 26, 2015 | Slide 253
Engineering and consulting
Advisory services from experts for life cycle

management of motors and generators
Energy efficiency and reliability appraisals show the
savings that can be achieved by replacing an existing
product with a more efficient and reliable unit
Transient mitigation services check the susceptibility of
your network to transients which could damage the
stator windings of motors
Other solutions are available for dealing with specific
problems that may arise at the site.

Maximized availability and reliability
Extended lifetime through use of most appropriate
maintenance practices
Minimized unplanned downtime
Controlled risks and costs associated with maintenance
Access to solutions based on patented and specialized
technology
Single source for consulting services and
implementation of solutions
ABB Group
May 26, 2015 | Slide 254
Service offering can be found at

www.abb.com/motors&generators
ABB Group
May 26, 2015 | Slide 255
Agenda
Chng trnh
Time - Thi gian
08:30 09:00
9:00 09:15
9:15 10:45
Content - Ni dung
Ta nh REE
10:45 11:00
11:00 12:00
11:45 12:00
13:00 13:30
13:30 15:15
Break - GIi lao

Lunch - Buffet tra
15:15 15:30
15:30 16:30
Break - Gii lao

Dch v k thut
16:30 17:00
ABB
May 26, 2015
| Slide 257

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Discrete Automation and Motion Division, May 27 2015

ABB Technical Workshop on Motors

Break - GIi lao

Break - Gii lao

Q&A & wrap up - Hi p & Kt thc chng trnh

Break - GIi lao

Break - Gii lao

Q&A & wrap up - Hi p & Kt thc chng trnh

Richard Yue, Discrete Automation and Motion Division, May 27 2015

A global leader in power and automation technologies

merger of Swiss (BBC, 1891)

Power and productivity for a better world

A leader in addressing power

A leader in operational asset

Contributing to decoupling growth from environmental impact

Less energy per unit GDP

Less pollution per unit energy

How ABB is organized

ABBs portfolio covers:

Motors and drives

Intelligent building systems

Robots and robot systems

Low voltage products

Services to improve customers productivity

ABB Vietnam Introduction

Low Voltage Products

Discrete Automation and Motion

VNABB is one of the Top 20 companies to work for in Vietnam.

DM and LP are growing fast and promising

Discrete Automation and Motion

Business units and offering

Drives and Controls

Low voltage AC drives from

October 31, 2013

Excitation and synchronizing

Low voltage motors from 0.25

Which market do we serve?

2013 global market value in US$ million

BU Motors and Generators

What we stand for

More than 100 countries

65 ABB service centers and more than

5,600 ABB external channels

1,600,000 products in 7 logistic centers

Spares and consumables

Faster start-up, optimized life cycle

Improved efficiency, reliability and

Increased availability and minimized

Maximized performance, reduced

On-site and workshop repairs by

Genuine OEM spare parts and

Analyze energy, performance

Our products work in all industries, all applications

Break - GIi lao

Break - Gii lao

Q&A & wrap up - Hi p & Kt thc chng trnh

Chiam Chee Seong

BU Motors and Generators

Basic Motor Technical &

Component Parts of a Motor

ABB BU Motors and Generators

The Making Process

ABB BU Motors and Generators

ABB BU Motors and Generators