TERRAMAX MOTORS TCM SERIES, XRI SDM MINING DUTY INDUSTRIAL MOTOR

Transcription

1 TERRAMAX MOTORS TCM SERIES, XRI SDM MINING DUTY INDUSTRIAL MOTOR

2 CONTENTS INTRODUCTION OVERVIEW & STANDARDS MECHANICAL DESIGN ELECTRICAL DESIGN PERFORMANCE DATA DIMENSIONAL DRAWINGS PACKAGING DETAILS 25 PART NUMBER LOGIC 26 MODIFICATIONS & OPTIONS 27 2

3 INTRODUCTION Marathon TerraMAX TCM series and XRI SDM series are IE3 or premium efficiency low voltage series motors specifically designed for the arduous conditions of the mining industry. These motors inherit the commitment of performance, quality and long lasting reliability of the global TerraMAX platform for the IEC and NEMA * motors applications and at the same time present a tough and robust feature set to cater to the demanding application requirements of the mining industry. Marathon XRI severe duty mining motor is designed and built for NEMA * construction with premium efficiency for the North American mining industry. Regal's global design team working across multiple continents has captured the requirements of our global customers to meet the application requirements across multiple regions of the IEC & NEMA motor world, and responded with this unique new motor platform Marathon TerraMAX cast Iron motors for IEC and NEMA mining industry. Stock, non-stock and build-up models Please contact your local sales person to get more information on models that are readily available in stock. For non-stock and build-up models, minimum quantity may be applicable for each region. Warranty Our world class manufacturing process and quality systems ensure that the Marathon TCM Series and XRI SDM Series motors are free from defect in material and workmanship. Please refer out terms and conditions of sales for warranty terms. STORAGE PROCEDURES In the event that long-term storage of motors is required, the following precautions and procedures are receommended. A. Keep motors clean Store indoors. Keep covered to eliminate airborne dust and dirt. Cover openings for ventilation and terminal connections etc. to prevent entry of rodents, snakes, birds and insects. B. Keep motors dry Store in dry area indoors. Temperature swings should be minimal to prevent condensation. Space heaters are recommended to prevent condensation. Treat unpainted flanges, shafts and fittings with a rust inhibitor. Check insulation resistance before putting motor into service. C. Keep bearings lubricated Once per month, rotate shaft several turns to distribute grease in bearing. If unit has been stored more than one year, add grease before start-up as per lubrication procedure. *NEMA is a trademark and/or trade name of National Electrical Manufacturers Association Corporation and is not owned or controlled by Regal Beloit Corporation. 3

4 OVERVIEW AND STANDARDS Marathon TerraMAX TCM series motors and Marathon XRI severe duty mining motors are based on TerraMAX low voltage motor platform and therefore hold the promise of performance, quality and long lasting reliability to all customers. The power range of the TCM Series and XRI severe duty motors covers 0.75kW to 900kW in voltages ranging from 200V to 690V for 50Hz and 60Hz operation. The motors meet the IE3 (or premium) efficiency requirements as per IEC :2014 when tested to the latest test standard IEC :2014. NEMA * MG-1 table for full load efficiency for 60Hz operation is harmonized with corresponding efficiency listed for 60Hz operation in IEC :2014. Marathon TerraMAX TCM series motors dimensionally confirm to IEC (AS/NZS 1359). Marathon XRI severe duty mining motors dimensionally confirm NEMA MG-1. Both IEC and NEMA product ranges are built using cast iron frame construction from IEC and NEMA frame respectively. PRODUCT SUMMARY IEC NEMA Output kW 1HP 200HP Pole 2-8P Enclosure Mounting Totally enclosed fan cooled Foot, flange and foot-flange Frame IEC NEMA *Voltage V Frequency 50Hz, 60Hz, variable frequency STANDARDS The table below lists the general standards for mining duty motors. For regions or industries that require specific features and standard deviation befitting their needs, please refer to performance and dimension tables on page IEC NEMA Efficiency MG-1 Part 12 Dimension MG-1 Part 4 Cooling MG-1 Part 6 Term. marking MG-1 Part 2 Noise level MG-1 Part 9 Vib. level MG-1 Part 7 Protection MG-1 Part 5 Test method IEEE 112-B Key regions efficiency standards The motors also comply with the specific regional standard listed below for test efficiency. Australia / New Zealand AS/NZS method A MEPS (table A3) as per AS Brazil NBR : 2008 Canada CSA C China GB/T 1032: 2012 India IS: 12615: 2018 USA IEEE 112B & CSA C Protection IP66 Formulae and conversion factors Insulation Class H Torque lb-ft = x N-m Ambient -30 C to 65 C Power HP = x kw Vibration Class A (precision on request) Temperature C = ( F 32) x 5/9 Duty S1 to S9 duty class Torque (kg-m) 974 x kw / RPM Service Factor 1.15 SF Torque (lb-ft) 5252 x HP / RPM *Other voltages on request. Brake torque (5252 x HP / RPM) x SF (SF=1.4) SF=2 to 2.5 for crane & hoists 4 *NEMA is a trademark and/or trade name of National Electrical Manufacturers Association Corporation and is not owned or controlled by Regal Beloit Corporation.

5 MECHANICAL DESIGN MOUNTING IEC and NEMA * mining duty motors are available in the configurations as per the table. Contact regional sales for any other mounting. NOTE: Vertical motor with shaft down to be specified with or without canopy. No exposure to direct sunlight. Specified mounting to be mentioned when the ordering motors. Actual motor mounting may influence protection class and bearing design. 7 B8 IM2071 IM2171 IM Standard shaft end B7 IM2061 IM2161 IM2161 B6 IM2051 IM2151 IM V6 V36 V36 V36 V3 V19 V19 1 V5 V15 V15 V15 V1 V18 V18 IV 0 III B3 B3/B5 B3/ B14A B3/ B14B B5 B14A B14B II IM10 IM20 IM21 IM21 IM30 IM36 IM36 I IM1 FOOT IM2 FOOT AND FLANGE IM3 FLANGE *NEMA is a trademark and/or trade name of National Electrical Manufacturers Association Corporation and is not owned or controlled by Regal Beloit Corporation. 5

6 Material and construction Stator frame Endshield Terminal box Fan Fan cover Fasteners Cast iron with integral foot Cast iron Cast iron Cast iron, metallic (Corrosion resistant coat) MS fabricated Corrosion protected Frame construction Marathon TerraMAX TCM series motors and Marathon XRI severe duty mining motor are built from high grade cast iron with minimum 200MPa tensile strength. The motor frame is deigned using the latest analytical tools followed by due validation. The integral foot construction ensures that the alignment of the drive shaft and motor feet remain secured under all working conditions, including the starting and maximum power output demands. The fins on the body are designed to dissipate optimum amount of heat for the lowest airflow over the body corresponding to higher pole count, resulting in lower windage loss and therefore higher efficiency. The spacing between the fins is also optimized to prevent accumulation and build-up of dirt. The terminal box location is centralized for right or left mount position. Top box mount is optional. Shaft Marathon TerraMAX TCM series motors and Marathon XRI severe duty mining motor are manufactured with a AISI 1045 (C45) tensile strength shaft material. The design is suitable to provide strength and rigidity during operation. Bearing journals are ground to ensure an accurate bearing fit and positioning. Full key is provided with each motor. Customer shaft extension run out, concentricity and perpendicularity to the face of standard flange mount motors comply with normal grade tolerance as specified in IEC and IEC Precision grade tolerance is available upon on specific request. Non-standard dimensions and shaft material is provided on specific request. Shaft Dimensions DIA mm TOL μm LEN mm KEY mm SEAT mm 19 9 / x6x / x7x / x7x / x8x / x8x / x9x / x10x / x11x DIA mm TOL μm LEN mm KEY mm SEAT mm / x11x / x12x / x12x / x14x / x14x / x16x / x16x / x18x All mining duty motors from IEC 200 (NEMA * 320) and above are fitted with shaft-locking arrangement to prevent false brinelling during transportation. The motors should always be transported or stored with this clamp arrangement and tensioned periodically to avoid bearing damage. Once the motor reaches its final destination and is ready for installation, the shaft-locking arrangement must be removed before the motor is run no-load to confirm that the bearings are in good condition. After this initial run, normal installation can continue with pulley or coupling. Endshields/ end-bracket The motor endshields are made from the same grade of cast iron as the stator frame. These are ribbed to provide a high level of cooling for the bearings. Their depth of the endshield is maintained less to ensure they remain sturdy under high stress during starting duty and maximum output condition. The design ensures that the endshield withstands the radial and axial forces encountered for most of the mining duty applications. Rotor The rotor is of squirrel cage design and constructed from diecast aluminum, dynamically balanced for smooth operation. Paint All casting and steel parts are primed with 2-pack epoxy coating, followed by a top coat of 2-pack epoxy. The standard mining motor paint shade is RAL 2008 (bright red orange). For motors with supply voltage at 1000V, the standard color is RAL 5019 (Capri Blue). The paint finish for all mining motors is suited for arduous environments and meets grade C3 as per ISO Special paint system can be provided on request to suit stringent requirements for motors in corrosive environments such as acid, salt water and extreme climatic conditions. 6 *NEMA is a trademark and/or trade name of National Electrical Manufacturers Association Corporation and is not owned or controlled by Regal Beloit Corporation.

7 Degree of protection Enclosure type Degree of protection Protection against mechanical particles Accidental contact Solid foreign particles Protection against water Open circuit cooled (ODP) IP23 contact with fingers contact with tools / object solid body > 12mm diameter against solid body > 1mm diameter water spray < 60 to vertical IP44 splashing water, all directions Totally Enclosed Fan Cooled (TEFC) IP54 IP55 IP56 IP65 IP67 IP68 complete protection against accidental contacts harmful dust deposits ingress of dust water jet from all directions non-heavy seas, strong jets heavy seas, strong jets water jet from all directions submersion (time & pressure) cont submersion as per manufacturer Marathon TerraMAX TCM series motors are rated to IP66 degree of protection, indicating a dust-tight enclosure (no ingress of dust) and protection against heavy seas (water from heavy seas or water projected in powerful jets shall no enter the enclosure in harmful quantities). Enclosure designation also complies with IEC and AS LABYRINTH SEAL The labyrinth gamma shaft seal provides two sealing points: on the shaft and on the bracket. Sintered bronze drain plugs with breather maintain the both the IP66 rating and reduce the impact of condensation. Cooling Marathon TerraMAX TCM series motors and Marathon XRI SDM motor are fitted with a patented low noise bidirectional cast iron or fabricated steel fan. With its unique design modelled on a shark fin profile, the fan is designed to minimize air turbulence within the fan cover and allow smooth airflow. During installation, care needs to be taken to not hinder the air flow to the inlet of the fan cover. In accordance with standard practice, the minium axial distance between the fan cover mesh and the closest barrier is about half the motor shaft height, which allows sufficient cool air and prevents recirculation. Applications that do meet these requirements should be referred to the technical support team. The fan and fan cover are designed to eliminate the need for special acoustic control to meet noise level in accordance with IEC For special applications such as low speed operation with a variable speed drive or for applications with frequent start and stop, a separately driven cooling fan can be fitted as optional feature. The fan cover is constructed from sheet steel and has the C3 level epoxy coating similar to the motor frame. It has been designed as a paired component with the patented fan to ensure optimum cooling for the motor at low noise with inbuilt strength. Frame Size IEC NEMA * BL - mm *NEMA is a trademark and/or trade name of National Electrical Manufacturers Association Corporation and is not owned or controlled by Regal Beloit Corporation. 7

8 Noise The cooling system comprising of fan and fan cover, as discussed in the previous section, is designed for optimal air flow with minimum losses and streamlined airflow. This enables the fan to maintain low noise levels. Sound pressure level (50 Hz ) - db(a) 8 IEC (NEMA) 2P 4P 6P 8P (210) (250) (280) (320) (360) (400) (445) (449) Sound pressure level (60 Hz ) - db(a) IEC (NEMA) 2P 4P 6P 8P (210) (250) (280) (320) (360) (400) (445) (449) Alternate devices for lower noise level available, when specified. Balancing The mining duty motors have rotors balanced separately from the external cooling fan, so that the fan can be removed or changed without altering the balance of the rotor. All rotors are balanced with a half key to fine tolerances (G2.5). Balancing to G1 tolerances is available on request. Vibration Mining duty motors comply with the limits of vibration severity as mentioned in IEC Values relate to rotating machinery measured in soft suspension. Frame IEC (NEMA) Vibration (mm/s) ( ) ( ) Vibration sensors Provision for fitting vibration sensors for condition monitoring is available on all Marathon TerraMAX TCM series motors and Marathon XRI severe duty mining motors. Bearing and lubrication All mining duty motors have high quality bearings made from vacuum degassed steel. The standard bearings in the range are selected to provide long operating life, quieter running and high load carrying capacity. NU type roller bearings are fitted to the drive end of 4P, 6P & 8P motors for IEC 250 (NEMA * 400) frame and above. All other bearings are deep groove ball bearings as shown in the table within this section. IEC (NEMA) DE STD DE OPT NDE STD ZZ 6204ZZ ZZ 6205ZZ ZZ 6206ZZ ZZ 6206ZZ Z NU Z NU NU (320) 6312 NU (360) 6313 NU , 2P (400-TS) , 4-8P (400T) NU , 2P (440TS) , 4-8P NU , 2P , 4-8P NU , 2P , 4-8P NU , 2P , 4-8P NU , 4-8P NU (180) 6206ZZ 6205ZZ (210) 6308ZZ NU ZZ (250) 6309ZZ NU ZZ (280) 6311ZZ NU ZZ (440T) NU Note: Special bearings for non-standard mounting GREASE PATH *NEMA is a trademark and/or trade name of National Electrical Manufacturers Association Corporation and is not owned or controlled by Regal Beloit Corporation. The drive end bearing is locked to prevent axial movement. Motors in IEC & NEMA frames have shielded bearings. IEC 355 & above frames use angular contact bearings for V1 mounting. The bearings are pre- lubricated with a lithium base grease. All motors with IEC 132 (NEMA 210) frame and above are fitted with grease nipples and have a flush-through pressure grease relief path, which allows the bearing to be re-lubricated without stopping the motor.

9 Marathon TerraMAX TCM series motors bearing size and re-lubrication data For motor frames 132 to 225 for 4 pole and above, in applications with increased radial force, ball bearings can be substituted for cylindrical roller bearings at the drive end, in accordance with the bearings table on this page. The tables on this page and subsequent pages give the relubrication details for bearing used for mining duty motors. IEC Frame Size Brg No Ball bearing Roller bearing Drive end bearing Non-drive end bearing Drive end bearing Relubrication Relubrication Relubrication Brg No Brg No Qty Interval Qty Interval Qty Interval 3000 R/MIN = 2 POLES R/MIN = 4 POLES NU NU NU NU NU NU NU NU NU NU NU R/MIN = 6 POLES NU NU NU NU NU NU NU NU NU NU NU R/MIN = 8 POLES NU NU NU NU NU NU NU NU NU NU NU

10 Standard ball bearing - maximum radial forces Fr [N] 10 Size Poles Xo X1/2 Xmax ,240 1, ,360 1,200 1, ,550 1,390 1, ,540 1,380 1, ,810 1,610 1, ,000 1,780 1, ,230 1,980 1, ,250 2,000 1, ,620 2,330 2, ,920 2,600 2, ,730 2,420 2, ,760 2,440 2, ,330 2,950 2, ,700 3,280 2, ,880 3,510 3, ,870 3,500 3, ,600 4,160 3, ,100 4,600 4, ,000 3,620 3, ,290 3,880 3, ,040 4,560 4, ,510 4,990 4, ,530 4,120 3, ,790 4,250 3, ,600 4,980 4, ,270 5,570 5, ,440 3,960 3, ,140 5,520 5, ,480 6,700 6, ,110 7,270 6, ,620 3,290 3, ,660 5,120 4, ,250 6,550 5, ,580 6,840 6, ,890 5,460 5, ,440 5,900 5, ,000 7,330 6, ,570 7,870 7, ,770 6,270 5, ,120 7,350 6, ,430 8,530 7, ,610 9,640 8, ,119 5,793 5, ,080 8,499 7, ,916 10,217 9, ,231 11,447 10, ,112 2,969 2, ,016 7,564 7, ,407 8,877 8, ,081 10,456 9,898 The table shows the Permissible Radial Forces in [N], assuming zero axial force and standard ball bearing or roller bearings when higher radial forces are required. The values are based on normal conditions at 50Hz and calculated at 20 K working hours for 2Pole motors and 40K working hours for 4, 6 and 8 pole motors. Reduce the values by 10% for 60Hz speeds. Roller bearing - maximum radial forces Fr [N] Size Poles Xo X1/2 Xmax ,100 5,430 4, ,930 6,160 5, ,600 6,750 6, ,370 6,530 5, ,500 7,530 6, ,280 8,220 7, ,500 9,490 8, ,000 10,870 9, ,110 11,870 10, ,180 10,120 9, ,730 11,520 10, ,840 12,530 11, ,530 12,030 10, ,410 13,730 12, ,890 15,040 13, ,970 17,100 15, ,760 19,550 17, ,610 21,180 19, ,150 19,150 17, ,560 22,160 20, ,330 23,760 21, ,340 22,290 20, ,090 25,720 23, ,360 27,820 25, ,430 35,040 32, ,470 39,640 36, ,570 43,430 39, , , , , ,000 23,600 15, ,000 20,900 13, ,000 23,900 15, ,000 26,800 17,700

11 Standard ball bearing at DE / NDE - maximum axial forces [N] Size Poles B3 B3 V1 Fpressure Fpull Load up V1 Load down , , , , , , , , , , , , , ,680 1,020 1, ,870 1,210 1,990 1, ,020 1,140 2,210 1, ,030 1,150 2, ,360 1,480 2,680 1, ,640 1,760 2,920 1, ,420 1,480 2,860 1, ,430 1,490 3,040 1, ,900 1,960 3,510 1, ,240 2,300 3,880 1, ,180 2,120 3,720 1, ,180 2,120 3,930 1, ,770 2,710 4,590 2, ,220 3,160 5,090 2, ,430 2,310 4,240 1, ,570 2,450 4,520 1, ,210 3,090 5,330 2, ,680 3,560 6,050 2, ,770 2,630 4,780 1, ,890 2,750 5,200 1, ,590 3,450 6,060 2, ,180 4,040 6,840 3, ,880 2,680 5,440 1, ,320 4,120 6,620 2, ,900 4,700 7,810 3, ,550 5,350 9,010 3, ,480 2,280 5, ,760 3,320 8, ,920 4,480 9,860 1, ,410 4,970 10,160 2, ,690 3,410 8,380 1, ,500 3,540 10,350 2, ,650 4,690 12,180 3, ,300 5,340 14,170 3, ,590 3,630 11,200 n/a ,110 3,970 16, ,240 5,100 17,680 1, ,240 6,100 19,950 2, ,900 2,100 n/a n/a ,600 3,900 15,000 1, ,400 4,800 16,000 1, ,700 5,000 18,000 2, ,500 1,500 n/a n/a ,000 4,500 20,000 3, ,000 5,000 22,000 4, ,000 5,500 24,000 5,300 Grey shaded - valid for 20K hours of bearing life. The table shows the permissible axial forces in (N), assuming zero radial force and standard ball bearing. When higher axial forces are required angular contact bearings should be fitted. The values are based on normal conditions at 50Hz and calculated at 20K working hours for 2pole motors and 40K hours for 4, 6 and 8 pole motors. Reduce the values by 10% for 60Hz speeds. 11

12 ELECTRICAL DESIGN Torque Characteristics Marathon TerraMAX TCM series motors and Marathon XRI severe duty mining motor are IE3 premium efficiency motors, specifically designed for heavy duty applications in the mining industry. The electrical performance of the motors is designed to meet the stringent requirements of mining duty applications and achieve a design life of 20 years. Voltage and frequency Motors can be designed for 200V to 1000V and for 50Hz or 60Hz supply frequency, based on the standard supply conditions in the region. The motor can also be operated at voltage other than the standard voltage. However, in such cases the rated performance values should be multiplied by factors in the table below to get more realistic performance data. The example below shows performance at alternate voltage for a 400V/50Hz motor. V (f) RPM O/P I FLT LRT BDT 380 (50) (50) (50) (50) (60) (60) Output torque of the motor is very critical for mining duty motor. A typical torque-speed characteristics is shown in the adjacent figure. All Marathon TerraMAX TCM and XRI severe duty mining motors exceed the minimum starting torque requirements for design N as specified in IEC The full load torque can be calculated with the formula indicated. Temperature output power specified in the performance data tables apply for standard ambient conditions of 40 C up to 1000m above sea level. Where temperature differs from the standard, multiplication factors in the table below should be used. 460 (60) Ambient Temperature Temperature Factor (60) For critical applications, data should be confirmed. Direction of rotation All mining duty motors are capable of operation in either direction of rotation. To reverse the direction of rotation interchange any two of the phase connections. For details on the terminal connection, refer the specific section in this brochure. The unique fan design modelled on the shark fin profile provides the required cooling at low noise in either direction of rotation. The standard direction of rotation is clockwise when viewed from driving end (DE). Service Factor Marathon TerraMAX TCM and XRI SDM motors are suitable to operate with 1.15 service factor at 40deg ambient for standard frame output relationships as per IEC The temperature rise on service factor duty would be limited to class F rise. For higher output in standard frames with service factor, contact Regal. 30 C C C C C C C 0.82 Effective power = rated power x temperature factor Duty Standard mining duty motors are suitable for S1 Duty operation. Motors can be designed for other duty cycle, supplied as build-up option. The working cycle of equipment can be classified into duty types in accordance with the table below, according to IEC The outputs in the subsequent tables in the catalogue are based on S1 duty at rated output. It is recommended to determine the duty cycle of the equipment for proper selection of the motor for the application.

13 N = Duration of operation under rated load F = Duration of electrical braking D = Duration of acceleration V = Duration of operation on no load R = Duration of rest and de-energized period To determine the correct motor size for duty cycles other than S1, contact Regal technical support team. Duty S1 Description Continuous running duty Cyclic duty factor - Typical application Pump, blower, fan The terminal box is designed oversize to accommodate fitting of larger than standard cables to minimize voltage drop over long cable runs. The bigger dimensions also allow aluminum cables to be terminated using bimetallic lugs. A removable gland plate is fitted to all terminal boxes for frame IEC 160 and above. For frames 80 to 315, the gland entry is drilled and tapped with standard metric threads as per the accompanying table. Motor frames IEC 355 and above are fitted with undrilled ferrous gland plates (non-ferrous is optional). The terminal box is supplied with the conduit entry facing downward and can be rotated through 360 in 90 increments for frame IEC 160 & above. For frames IEC , the terminal box can be rotated in 180 increments. S2 Short time duty - S3 S4 S5 S6 S7 Intermittent periodic duty Intermittent periodic duty with starting Intermittent periodic duty with starting and electric braking Continuous with intermittent periodic loading Continuous duty with starting and braking N/(N+R) (D+N)/ (D+N+R) (D+N+F)/ (D+N+F+R) N/(N+V) - Sluice gates, capstan Wire drawing m/c Hoists, cranes Hoists, rolling mills Conveyors Machine tools IEC Frame Qty Entry Pitch Size M20 X M25 X M32 X M40 X M50 X M63 X Black gland plate Winding and connections The winding of the motors consists of modified polyester enamel covered copper wire suitable for the class of insulation and starting duty requirement of the motor to withstand high starting current. S8 S9 Continuous periodic duty related load speed changes Duty with nonperiodic load and speed variations Combination of CDF - All motors 3kW and below are connected in star while motors over 3kW are wired in delta as standard. Standard connection has 6 leads in the terminal box with connecting links to facilitate different starting methods based on the application suitability. Some of the terminal connections are indicated below. S10 Duty with discrete constant loads an speed - CDF = Cyclic Duty Factor Terminal box Cast iron diagonally split terminal boxes are provided on all Marathon TerraMAX TCM and XRI severe duty mining motor. The terminal box is mounted centrally on the stator frame, allowing late point change of the terminal box from right to left, except IEC 400 & 450 frames. Optionally, top mounted terminal boxes are available on request. 13

14 Motor starting All Marathon TerraMAX TCM and XRI severe duty mining motors are suitable for starting by DOL, Star/ Delta starter or electronic soft starter. Motors are suitable for all standard methods of starting. It is imperative however to ensure that the starting torque and current limitations of each starting method be considered along with the motor performance curves to finalize the suitable starting method for a given application. DOL starting Direct on Line starting or starting across the line is the most simplest method of starting. The limitation of this method is higher starting current and sudden starting jerk due to high starting torque. In specific applications this may result in stresses on the coupling and driven application. Below rated frequency, the motor is in constant torque range. Above rated frequency the motor is in constant power range. When operating with a VVVF drive the TerraMAX TCM motor care must be taken to ensure appropriate motor cooling is provided at low speed. The load-ability curve TerraMAX TCM is shown below. Where the low speed load requirement of the application is beyond the curve then forced cooling may be required. Star-Delta starting in cases where the starting current needs to be limited due to supply conditions star-delta starting may be used. The current reduced to about 30% and torque to about 25% of the value on DOL. The connection switches to delta when rated speed is achieved. Soft starter starting this is more commonly used method when smooth starting is required. This is achieved by limiting the starting current and thereby limiting the torque. Gradual increase of the current accelerates the load to full speed over a longer starting period. Operation with variable speed drives Variable voltage variable frequency (VVVF) drives are primarily recognized for their ability to manipulate power from a constant 3 phase 50/60Hz supply converting it to variable voltage and variable frequency power. This enables the speed of the motor to be matched to its load in a flexible and energy efficient manner. The only way of producing starting torque equal to full load torque with full load current is by using VVVF drives. The functionally flexible VVVF drive is also commonly used to reduce energy consumption on fans, pumps and compressors and offer a simple and repeatable method for changing speeds and flow rates. An example of a motor speed/torque characteristic on a VSD is shown below: The switching characteristics of the power semiconductor devices of a VVVF can lead to peak voltages in excess of rated voltage of the motor with short rise times and generates common-mode voltage which lead to currents flowing within the motor and shaft voltages. An insulated endshield on the non-drive end and a shaft earthing device make the TerraMAX TCM suitable for operation on a VVVF. This is recommended for motors 315 frame and above. Insulation and varnish Insulation is a key component of any electric motor and due attention to the insulation system suitable for the application and environment is critical to ensure reliable operation and long life of the motor. Insulation system comprises of electric magnet (winding) wire, slot and phase insulation, varnish or resin for winding impregnation, insulating sleeves, insulation over the joints and good workman ship. While insulating material are classified into Y-A-E-B- F-H-C thermal class based on increasing temperature limit for each thermal class. TerraMAX TCM series motors are wound with H Class insulation varnished based on the Vacuum Pressure Impregnation (VPI) system and winding designs limit the temperature rise to 80K (unless otherwise noted). The use of H Class insulation provides an additional safety margin of 45K, as shown in the accompanying table, together with a design life in excess of 20 years. 14

15 IEC HOT (sec) COLD (sec) IEC HOT (sec) COLD (sec) Tolerance on electrical performance Electrical performance of a motor is subject to tolerance as per IEC (AS NZS ), to account for the variation in material, processes and supply conditions. 150kW > 150KW Due to their conservative design many sizes in the TCM range of motors have temperature rises considerably less than 80K and therefore provide even greater safety margins. Efficiency -15% (1-η) -10% (1-η) Power factor -1/6 (1- cosф) Locked rotor amp +20% of the current Thermal protection - thermistors All mining duty motors are fitted with one PTC thermistor per phase, selected for a tripping temperature of 150 C. For IEC frame 80 to 132, the thermistors are terminated within the main terminal box. IEC frames 160 and above, the thermistors are terminated in the auxiliary terminal box on the right. Locked rotor torque Pull up torque Moment of inertia Noise level [-15% +25%] of the torque -15% of the value ±10% of the value +3 db(a) Thermal protection RTD s An additional method of monitoring temperature is to fit 3 wire PT100 Resistance Temperature Detectors (RTDs). RTDs are terminated in an auxiliary terminal box affixed to the main terminal box. Winding RTDs are standard in IEC 315 frame and above RTD s are optional for smaller frames. Bearing RTDs are optional from 200 frame and above. < 1kW 1KW Slip ±30% ±20% Voltage and frequency variations are classified as Zone A or Zone B as per IEC as indicated in the figure below. Anti-condensation heaters All mining duty motors IEC frames 250 and above are fitted with anti- condensation heaters (optional on smaller sizes). These heaters are suitable for V operation and can be supplied connected for V operation against specific orders. The heaters are terminated in the auxiliary terminal box towards the left. Thermal withstand time The starting time of the motor is dependent on the load torque, inertia and motor torque. Due to high starting current there are limitation on the number of hot or cold starts that a motor can withstand and the time within which a motor should attain rated speed such that the current drops to rated value. It is therefore to determine the starting time of critical application in the design stage itself and ensure that it is well within the thermal withstand time of the motor in hot and cold conditions respectively. As per IEC an electric motor must be suitable to deliver torque contiguously in zone A. However, under this condition the motor may operate at a temperature rise above its rated value, due to power supply variations. The motor must also deliver required torque in zone B. However, there would significant performance changes and the temperature rise will he higher than zone A. Long term operation in zone B is not recommended. 15

16 PERFORMANCE DATA - 2 POLE Model no. Motor frame (kw) Speed [r/min] Full load Amp Power factor 50Hz Supply Efficiency 380V 400V 415V 100% 75% 50% 3000 R/MIN = 2 POLES Starting Current Starting Torque Breakdown Torque Moment of Inertia (kgm 2 ) Weight (kg) TCMP751A GAC010 80M TCM1P11A GAC010 80M TCM1P51A GAC010 90S TCM2P21A GAC010 90L TCM0031A GAC L TCM0041A GAC M TCM5P51A GAC S TCM7P51A GAC S TCM0111A GAC M TCM0151A GAC M TCM18P1A GAC L TCM0221A GAC M TCM0301A GAC L TCM0371A GAC L TCM0451A GAC M TCM0551A GAC M TCM0751A GAC S TCM0901A GAC M TCM1101A GAC S TCM1321A GAC M TCM1601A GAC L TCM2001A GAC L TCM2501A GAC M TCM3151A GAC L TCM3551A GAC L TCM3751A GAC L TCM4501A GAC S TCM5001A GAC X TCM5601A GAC X HIGHER OUTPUT MODELS - SERVICE FACTOR 1.0 TCM2251A HAC L TCM2501A HAC L TCM4001A HAC L Note: Contact Regal for 60Hz performance data. 16

17 PERFORMANCE DATA - 4 POLE Model no. Motor frame (kw) Speed [r/min] Full load Amp Power factor 50Hz Supply Efficiency 380V 400V 415V 100% 75% 50% 1500 R/MIN = 4 POLES Starting Current Starting Torque Breakdown Torque Moment of Inertia (kgm 2 ) Weight (kg) TCMP752A GAC010 80M TCM1P12A GAC010 90S TCM1P52A GAC010 90L TCM2P22A GAC L TCM0032A GAC L TCM0042A GAC M TCM5P52A GAC S TCM7P52A GAC M TCM0112A GAC M TCM0152A GAC L TCM18P2A GAC M TCM0222A GAC L TCM0302A GAC L TCM0372A GAC S TCM0452A GAC M TCM0552A GAC M TCM0752A GAC S TCM0902A GAC M TCM1102A GAC S TCM1322A GAC M TCM1602A GAC L TCM2002A GAC L TCM2502A GAC M TCM3152A GAC L TCM3552A GAC L TCM3752A GAC L TCM5002A GAC S TCM5602A GAC X TCM6302A GAC X HIGHER OUTPUT MODELS - SERVICE FACTOR 1.0 TCM2202A HAC L TCM2502A HAC L TCM2802A HAC L TCM4002A HAC L TCM4502A HAC L Note: Contact Regal for 60Hz performance data. 17

18 PERFORMANCE DATA - 6 POLE Model no. Motor frame (kw) Speed [r/min] Full load Amp Power factor 50Hz Supply Efficiency 380V 400V 415V 100% 75% 50% 1000 R/MIN = 6 POLES Starting Current Starting Torque Breakdown Torque Moment of Inertia (kgm 2 ) Weight (kg) TCMP753A GAC010 90S TCM1P13A GAC010 90L TCM1P53A GAC L TCM2P23A GAC M TCM0033A GAC S TCM0043A GAC M TCM5P53A GAC M TCM7P53A GAC M TCM0113A GAC L TCM0153A GAC L TCM18P3A GAC L TCM0223A GAC L TCM0303A GAC M TCM0373A GAC M TCM0453A GAC S TCM0553A GAC M TCM0753A GAC S TCM0903A GAC M TCM1103A GAC L TCM1323A GAC L TCM1603A GAC M TCM2003A GAC M TCM2503A GAC L TCM3553A GAC S TCM4003A GAC S TCM4503A GAC X TCM5003A GAC X TCM6303A GAC X Note: Contact Regal for 60Hz performance data. 18

19 PERFORMANCE DATA - 8 POLE Model no. Motor frame (kw) Speed [r/min] Full load Amp Power factor 50Hz Supply Efficiency 380V 400V 415V 100% 75% 50% 750 R/MIN = 8 POLES Starting Current Starting Torque Breakdown Torque Moment of Inertia (kgm 2 ) Weight (kg) TCM0754A GAC L TCM1P14A GAC L TCM1P54A GAC M TCM2P24A GAC S TCM0034A GAC M TCM0044A GAC M TCM5P54A GAC M TCM7P54A GAC L TCM0114A GAC L TCM0154A GAC L TCM18P4A GAC S TCM0224A GAC M TCM0304A GAC M TCM0374A GAC S TCM0454A GAC M TCM0554A GAC S TCM0754A GAC S TCM0904A GAC S TCM1104A GAC M TCM1324A GAC M TCM1504A GAC M TCM1604A GAC M TCM2004A GAC L TCM2804A GAC S TCM3154A GAC S TCM3554A GAC X HIGHER OUTPUT MODELS - SERVICE FACTOR 1.0 TCM2204A HAC L Note: Contact Regal for 60Hz performance data. 19

20 DIMENSIONAL DRAWINGS IEC MOTORS, FOOT MOUNTED (B3) Frame Pole A AA AB AC AD B BB C D DB E F GD G H HA HD HE HF K KK L 80M All M M S All M M L All / M M L All M M M All / M M S All M M M All / M M M All M M L All / M M M All M M L All / M M L All / M M S M M M / M M M / M M M / M M50 941/ M / M M50 941/ S M M M / M M / M / M M / M / M M M / M M L / M M L / M M L / M BGP L / M BGP S / M BGP S / M BGP X /800/ M X47 BGP X /800/ M X47 BGP X / /1250 Note: All dimensions in mm M X75 BGP 2400

21 DIMENSIONAL DRAWINGS IEC MOTORS, FLANGE MOUNTED (B5) Frame Pole AC AD D DB E F GD G HE HF KK L LA M N P S T 80M All M M S All M () M L All M () M L All M M M All M M S All M M M All M M M All M M L All M ()3 241 M M All M M L All M M L All M M S M M M M M M M M M 2P M M50 941/ M M M50 941/ S M M M M M / M M M / M M M M M M L M M L M M L M BGP L M BGP S M BGP S M BGP X M BGP X M BGP X M BGP Note: All dimensions in mm. 21

22 DIMENSIONAL DRAWINGS IEC MOTORS, FOOT & FLANGE MOUNTED (B35) 22 Frame Pole A AA AB AC AD B BB C D DB E F GD G H HA HD HE HF K KK L LA M N P S T 80M All M M S All M M L All / M M L All M M M All / M M S All M M M All / M M M All M M L All / M M M All M M L All / M M L All / M M S M M M / M M M / M M M / M M50 941/ M / M M50 941/ S M M M / M M / M / M M / M / M M M / M M L / M M L / M M L / M BGP L / M BGP S / M BGP S / M BGP X /800/ X /800/ X 6 750/ M X47 BGP M X47 BGP /1000/ M X75 BGP /1250 Note: All dimensions in mm.

23 DIMENSIONAL DRAWINGS NEMA * MOTORS, FOOT MOUNTED (B3) Frame 2E 2F H BA A B C D G J O P T R S ES U N-W AB HB HK LL LM AA 182T T T T T T NPT 3/ NPT NPT TS T TS T TS T TS T TS T TS T TS / T TS T / TS / T Note: All dimensions in inches. *NEMA is a trademark and/or trade name of National Electrical Manufacturers Association Corporation and is not owned or controlled by Regal Beloit Corporation NPT NPT NPT NPT NPT NPT 3 23

24 DIMENSIONAL DRAWINGS NEMA * MOTORS, C-FACE MOUNTED (B14) Frame 2E 2F H BA AJ AK BD 182TC TC BF Hole 4 x UNC 1/ x UNC 1/2-13 BB BC AH A B C D G J O P T R S ES U N-W AB HB HK LL LM AA NPT 3/4 213TC NPT 1 215TC x UNC 1/ TC TC TSC TC x UNC TSC / TC TSC TC x UNC TSC / TC NPT 1.25 NPT NPT 2 364TSC TC x UNC NPT TSC / TC TSC TC UNC 5/ / 8 x NPT 3 445TSC / x TC NPT UNC TSC / 5/ TC NPT 3 Note: All dimensions in inches. *NEMA is a trademark and/or trade name of National Electrical Manufacturers Association Corporation and is not owned or controlled by Regal Beloit Corporation. 24

25 PACKAGING DETAILS IEC AND NEMA * Z TerraMAX TCM motors are in frames IEC 80 & 90, are packaged in cardboard boxes for individual motors & then complete packaging is done in wooden crates. For frames IEC 100 to 132 and NEMA 180 to 210, the motors are packaged in cardboard boxes along with wooden pallet and then complete packaging is done in wooden crate box. For frames IEC 160 to 450 and NEMA 250 to 449, the motors are packaged in wooden crates. Framewise external dimensions and approximate weights are tabulated in the below tables. IEC frame size Individual package size (mm) Complete package size (mm) Packge quantity Approx. weight L x W x H L x W x H Nos kg 80M 300 x 275 x x 940 x S/L 355 x 295 x x 800 x L 425 x 350 x x 940 x M 425 x 350 x x 940 x S/M 530 x 405 x x 940 x M/L x 570 x M/L x 620 x L x 690 x S/M x 750 x M x 860 x S/M x 930 x S/M x 1080 x L x 1080 x L x 1180 x S x 1490 x X x 1490 x X x 1570 x IEC & NEMA FRAMES Individual motor packaging Cardboard box & wooden pallet Cardboard box Complete package NEMA frame size Individual package size (mm) Complete package size (mm) Packge quantity Approx. weight L x W x H L x W x H Nos kg 182/184T 440 x 343 x x 900 x /215T 535 x 416 x x 940 x /256T x 615 x /286TS & 284T x 645 x T x 645 x /326TS & 324T x 750 x T x 750 x /365TS & 364T x 780 x T x /5TS & 404/5T x 890 x /45TS x 970 x /45T x 970 x /9TS x 1000 x /9T x 1000 x *NEMA is a trademark and/or trade name of National Electrical Manufacturers Association Corporation and is not owned or controlled by Regal Beloit Corporation. Wooden crates IEC AND NEMA FRAMES Wooden crates 25