Motors Automation Energy Transmission & Distribution Coatings. W22 Brake Motor Three-phase Electric Motor

Transcription

1 Motors Automation Enery Transmission & Distribution Coatins W22 Brake Motor Three-phase Electric Motor --

2 Efficiency and reliability for the industry Founded in 1961, WEG is reconized today as one of the world s larest electric motors manufacturer, present in more than 100 countries at the five continents and countin on more than 25,000 employees, producin more than 10 million motors per year. Offerin a wide rane of motors, WEG also stands out in the supply of dedicated applications. Always focused on the customer s needs, it offers solutions for many different applications. WEG motors provide hih efficiency, low operatin costs, extended service life, and, above all, safety! 2 W22 Brake Motor

3 Visual index Main motor parts 1 Sealin system 8 Fan 2 Endshields 9 Bride rectifier 3 Bearins 10 Terminal block 4 Shaft 11 Terminal box Eyebolt 13 Stator 7 Fan cover 14 Shaft key Main brake parts 1 Fastenin screw 6 Retainin rin 2 Release lever 7 Hub 3 Brake stator (electromanet) 8 Key 4 Brake disc 9 Sealin system 5 Brake seal 10 ND-endshield W22 Brake Motor 3

4 W22 Brake Motor: new platform, new brake, excellent performance! In order to obtain productivity and hih performance, a company must count on reliable equipment, operatin in accordance with its purpose. That is the essence of the W22 brake motor: provide the production process with synery and aility. Featurin a new brakin system, hih torque and durability, the W22 brake motor is ideal for equipment that requires fast stops for safety, accurate positionin and time savin. The new brake motor introduces new characteristics in the brakin system and platform, which now counts on the same innovative features that make the W22 line a reat success: structure that reduces air dispersion and improves the coolin Terminal box with reater internal space and easy handlin Solid feet that simplify the motor alinment and installation providin hih mechanical strenth and low vibration levels 4 W22 Brake Motor

5 Features Standard Rated output: 0.25 HP to 75 HP Number of Poles: 2 to 8 size: 143T to 364/5T Frequency: 60 Hz Voltae: /460 V Brake power supply: V Normally closed brake Desin: B (Hih Efficiency or NEMA Premium Efficiency) A (Standard Efficiency or Super Premium Efficiency) Insulation class: F (DT 80K) Deree of protection: IP55 Mountin: F1 Coolin method: TEFC (Totally Enclosed Fan-Cooled) - IC411 and terminal box material: Cast iron FC-200 Fan material: Plastic (frames 143T to 215T) Aluminum (frames 254T to 364/5T) Shaft material: AISI 1040/45 Ball bearins Manual brake release (up to frame 326T) DE bearin seal: V-rin (frames 143T to 326T) WSeal (frame 364/5T) NDE bearin: Lip seal Paintin plan: 207A (frames 143T to 215T) and 203A (from frame 254T up), classified as corrosion cateory C2, accordin to ISO 12944:2 Optional Mountin: F2, F3 flanes, footless, vertical Deree of Protection: IP56, IP65, IP66 Frequency: 50Hz Voltae: 575 V and others DE bearin seal: W3 Seal, taconite seal, INPRO/SEAL Vibration level: Deree B (accordin to NEMA MG-1) Windin thermal protection: thermostat or thermistor Space heater Cable land Drip cover Tropicalized internal paintin Encoder Stainless steel screws Coolin method: TEBC Totally enclosed blower cooled (IC 416) Insulation class: H Able to operate with variable frequency Inverter* Microswitch to monitor the air ap or brake openin (from frame 182T up) Brake power supply: V V V Additional terminal box for frames 254T to 364/5T *For motors able to operate with variable frequency Inverter, WEG recommends the use of thermal protection on the windin. W22 Brake Motor 5

6 Optimizations of the brakin system New brake The friction element of the new brake provides less wear and more safety Interchaneable with other lobal brands Guarantee of fast and accurate stops System with fewer movin parts reduces downtime for maintenance Manual release lever Motor shaft may remain free in emerency situations or when necessary Standard torques The torques are established by frame so as to provide shorter brakin times Microswitch (optional) Rectifier Sensor to monitor the openin (I/O) or wear of the brake It indicates when to replace the friction disc, eliminatin the need of manual monitorin It can operate with voltae variations of up to 10% Robust and compact construction that allows installation in the motor main terminal box 6 W22 Brake Motor

7 General features Ideal for applications that require immediate, accurate and safe stops, position control and enery savin. The W22 brake motor is suitable for many different applications, such as load elevators, hoists, shears, machinin equipment, looms, packain machines, conveyors, washin and bottlin machines, bendin machines, amon others. How does a brake work? In order to ensure fast and accurate stops, the system of the W22 brake motor works as follows: when the motor is disconnected from the line, the current of the brake coil is also interrupted, which makes the coil stop actuatin. Then, the sprins push the armature towards the motor, compressin the brake disc between the armature and the ND-endshield, thus brakin the motor. The alternatin current (AC) power supply for the bride rectifier can be obtained from an independent source, or from the motor terminals, provided the motor is not supplied by frequency inverter. This power supply can be 220/230/240 V, 380/400/415 V, or 440/460/480 V, accordin to the features of the bride rectifier/brake coil assembly. The electromanetic coil can be operated continuously within ± 10% of its rated voltae. Armature plate Brake coil Brake disc ND-Endshield Air ap (S L ) Compression Sprin Bride rectifier Fiure 1 - Scheme of the brake components. When Power is applied, the system simultaneously starts the motor and powers up the brake coil. The armature is attracted aainst the frame of the brake coil, overcomin the pressure of the sprins and releasin the brake disc, which moves in the axial direction away from the friction surface. Thus, the brakin action ceases and the motor is free to start. Electromanet coil power supply The electromanet coil is powered by direct current (DC) which can be supplied by a DC voltae source or bride rectifier which converts AC to DC current. The bride rectifier consists of diodes and varistors that filter undesirable voltae spikes and enable fast current shutdown. The direct current power supply provides hiher speed and reliable brake operation. Fiure 2 - Detail of the bride rectifier inside the terminal box. If the brake coil is supplied by direct current, it must be directly connected to the brake terminals. W22 Brake Motor 7

8 Brakin system The W22 brake motor allows two brakin system: normal brakin or fast brakin. Normal brakin The bride rectifier of the brake coil can be supplied directly from the motor terminals, without interruption, as shown in Fiure 3. N L1 L2 L3 BR - Bride rectifier ~ Power and resistance of the brake stator Brake size 143/ / / / / /6 364/5 25 Brake voltae [V] Electric power [W] Resistance [ohm] , , Table 2 - Power and resistance of the brake stator. M 3 ~ Fiure 3 - Connection diaram of the bride rectifier for normal brakin. Fast brakin For fast brakin, the bride rectifier must be connected as shown in Fiure 4. Optional accessories In order to ensure even more safety and convenience for the application, the W22 brake motors can be supplied with some special features: Manual release lever It allows the motor shaft to be released in emerency cases or power outaes. It can be supplied for motors up to frame 326T. N L1 L2 L3 BR - Bride rectifier ~ M 3 ~ Fiure 5 Detail of the manual release lever. Fiure 4 - Connection diaram of the bride rectifier for fast brakin. Air ap adjustment In order to ensure proper operation of the brake, it is important to check and adjust the air ap (space between brake armature and frame), accordin to the values of Table 1. Brake size +0.1 Air ap ( ) [mm] 143/ / / / / /6-364/ Note: Under normal operatin conditions, the lever cannot be activated. Microswitch From frame 182T up, the motors can be supplied with a monitorin sensor of the openin (I/O) or wear of the brake. Monitorin of the openin: ensures that the motor will not start if the brake is actuated (it prevents motor starts with the shaft locked); Monitorin of the wear: indicates the riht moment to adjust or replace the brake linin. Table 1 - Values to adjust the air ap. 8 W22 Brake Motor

9 How to choose a W22 brake motor The W22 brake motor is a motor for quite specific applications that demand hih safety and accuracy. Therefore, it is extremely important to take into account some criteria when choosin such equipment. Basic data to make the best choice: Determine the motor and the brake: the first step is to define the environment in which the equipment will be used so as to select the motor with the best electromechanical characteristics for the application. The type of brake must also be checked, informin the power supply and the required brakin torque. Define the ambient temperature: takin into account the ambient temperature at which the motor will operate, we can determine the minimum ideal coolin system for the brake operation, accordin to table 3. Ambient temperature Minimum coolin system of the motor Up to 40 C No ventilation / W-Easy Maintenance Up to 50 C Self-Ventilated / Air Over Up to 60 C Blower cooled Up to 70 C Blower cooled* Table 3 - Definition of the coolin system accordin to the motor ambient temperature. * For this condition, please contact WEG. For other coolin system confiurations, contact WEG. Specify the deree of protection: the enclosures of electrical equipment, accordin to the characteristics and access conditions of the installation environment, must offer a certain deree of protection. Thus, equipment to be installed in a place subject to water jets, for example, must have an enclosure capable of withstandin such jets under certain pressures and anles of incidence without water inress. Table 4 indicates the minimum coolin system necessary to ensure the deree of protection. For other confiurations, contact WEG. Define the brakin torque. The W22 brake motor line offers up to two torques per frame: Rated torque: standard torque supplied; Optional torque: used in load liftin applications, or where, due to the hih load torque and/or inertia of the system, it is necessary the use of reater brakin torques. Available brakin torques (Mk). The brakin torque must be equal to or reater than the motor rated torque. Table 5 contains the main characteristics of the brakes, usin the speed of 100 rpm as reference. Torque at 100 rpm [ft.lb] Rated torque Optional torque Maximum workin speed [rpm] Maximum dissipated enery Q e [J] Table 5 - Characteristics of the brake accordin to the size and torque at 100 rpm. Brake response time t 12 [s] 143/ ,000 12, / ,600 30, / ,600 36, / ,600 60, / ,600 80, / , , / Deree of protection IP55 IP56/IP65/IP66 Minimum coolin system of the motor No ventilation / Air Over (with fan cover) Self-ventilated With or without release lever Self-ventilated with brake protection cover Without release lever W-Easy Maintenance With or without release lever Table 4 - Derees of protection and minimum coolin systems of the motor. W22 Brake Motor 9

10 Safety factor (k): For reular applications, WEG recommends the use of the safety factor k of 1.5 to 2 times the torque value. For special applications, such as liftin, it is recommended a safety factor k of 2 to 3 times the rated torque. Correction of the torque due to the speed at the moment of the brake (M R ): in cases of emerency stops (at workin speed) or in motors without frequency inverter, the motor rated speed is considered the brakin speed. Thus, the brakin torque must be corrected as indicated in Table 7. Check the brake power supply: The W22 brake motor can be supplied with full, half wave or special bride rectifiers, as shown in Table 6. Rared voltae V RMS [Vca] Tabela 6 - Bride rectifier types. Brake size Brake coil voltae [Vcc] to Calculations for special applications Calculation of the required torque for load liftin. For vertical applications, the brakin torque must be obtained by means of the required torque calculation (M req ), which is iven by the followin expression: M req = k * J L * Δno + M L 9.55 * t 3 - t 12 2 Wave form Where: M req : required torque [Nm]; k : safety factor that must be added due to the uncertainties of the speed at the brake, maximum torque, maximum load inertia, amon other variables. J L : total inertia on the rotor shaft = load inertia + system inertia + motor inertia [km 2 ]; Δno: speed [rpm]; t 3 : required brakin time [s]; t 12 : brake response time [s]. Full Half wave Calculation of the required torque for application in translational motion of overhead cranes. For horizontal applications, the brakin torque must also be obtained by means of the required torque calculation (M req ), which is iven by the followin expression: s Brake Torque correction at speed (rpm) [%] size , Table 7 - Torque correction. For brakes with frequency inverter, it is necessary to know the speed at which the brake will be performed, and the brakin torque must be corrected if necessary. M R = M req * 100 correction (%) Finally, it must be checked if the corrected required torque is equal to or smaller than the torque of the selected brake. If it is bier, it will be necessary to increase the torque of the brake. M K M R Check the coolin of the brake: after selectin the brake, it is necessary to check if the coolin will meet the start duty cycle of the application. The coolin can be obtained throuh the followin equation: Where: Q: dissipated heat [J]; M K : brake torque [Nm]; M L : load torque [Nm]. Q = J L * Δno 2 * M K M K - M L With the result found, the value of Q must be positioned on the axis of ordinates and the number of starts per hour on the axis of abscissa, and then we should observe if the point is below the curve of the selected brake. If it is below the curve, it indicates that the brake is thermally able to brake the load. Otherwise, the size of the brake must be increased so as to improve the coolin. M req = k * J L * Δno 9,55 * t 3 - t W22 Brake Motor

11 Brake size Q perm in [J] Operation frequency S h [h -1 ] Fiure 6 Coolin curve (Q) accordin to starts per hour. Brake power supply. When the brake coil is powered by a bride rectifier, the rectifier input terminals must be supplied with AC voltae. The relations between the motor voltae, the type of bride rectifier and the brake coil power supply must be in accordance with table 8. Motor power supply (connection) [VAC] Power supply of the brake bride rectifier [VAC] Brake type Normal Fast Supply of the bride rectifier throuh the motor electrical connections (IEC-NBR / NEMA) Terminal 1 (**) 3-wire motor Terminal 2 (**) 6-wire motor 9-wire motor 12-wire motor 220/230/240 (T) W1 / T3 W1 / T3 W1 / T3 W1 / T3 220/230/ /400/415 (Y) NA W2 / T6 NA W4 / T12 380/400/415 (T) 380/400/415 W1 / T3 W1 / T3 W1 / T3 W1 / T3 440/460 (Y) NA Fiure 3 Fiure 4 U1 / T1 NA NA NA NA 440/460 (T) 440/460 W1 / T3 W1 / T3 W1 / T3 W1 / T3 525/550/575 (Y) NA NA NA NA NA 525/550/575 (T) 525/550/575 W1 / T3 W1 / T3 W1 / T3 W1 / T3 Table 8 - Power supply of the bride rectifier throuh the motor terminals. T = Delta connection Y = Star connection NA = Not available * The bride rectifier can be directly supplied by the motor cables or independently, at the customer s discretion. ** Terminal markins are only valid for sinle speed motors. Note: besides the previous options, the electromanetic brake with 24-Vdc coil is also available. In this case, only the brake is included (bride rectifier not supplied) and the brake coil must be powered by an independent source. W22 Brake Motor 11

12 Performance Data W22 Brake Motor - Standard Efficiency Full Locked Locked Breakdown Allowable 460 V Output Load Inertia locked rotor Weiht Sound Service % of full load Full Torque Current J Rated Torque Torque time (s) (lb) db(a) Factor (lb*ft (ft.lb) Tl/Tn Tb/Tn 2 ) speed Efficiency Power Factor load current HP kw Code Il/In Hot Cold (rpm) In (A) X Pole T K T J /5T L /4T 1.03 L T 1.56 K /5T 2.08 K /5T 3.09 L T 4.12 J /6T 5.19 J T 6.09 J /6T 7.62 J /6T 10.2 J /6T 12.7 H /5T 20.3 J Hih-Output Desin T 10.2 J T 12.7 H XII Pole T 26.6 H /6T 35.4 G T 44.3 K /6T 53.6 K /6T 66.4 L /6T 88.6 K /5T 110 J /5T 132 J Hih-Output Desin T 88.6 K /5T 177 J W22 Brake Motor

13 W22 Brake Motor - Hih Efficiency Full Locked Locked Breakdown Allowable 460 V Output Load Inertia locked rotor Weiht Sound Service % of full load Full Torque Current J Rated Torque Torque time (s) (lb) db(a) Factor (lb*ft (ft.lb) Tl/Tn Tb/Tn 2 ) speed Efficiency Power Factor load current HP kw Code Il/In Hot Cold (rpm) In (A) II Pole /5T 1.49 K /5T 2.25 J /5T 3.00 J /4T 4.44 H /4T 7.42 H /5T 11.1 H /5T 14.8 G /6T 22.1 G /6T 29.4 G /6T 36.7 F /6T 44.0 F /6T 58.7 G Hih-Output Desin T 1.49 K T 1.49 K T 2.25 J T 2.25 J T 3.00 J T 2.96 J /4T 2.96 J /5T 4.51 H T 4.51 H T 4.44 H T 4.44 H T 7.42 H /4T 11.2 H T 11.2 H T 11.1 H T 11.1 H T 14.8 G /5T 22.3 G T 22.3 G T 22.1 G T 22.1 G T 29.4 G T 29.4 G /6T 36.8 G T 36.8 G TS 36.7 F TS 36.7 F TS 44.0 F TS 44.0 F TS 58.7 G TS 58.7 G W22 Brake Motor 13

14 Performance Data W22 Brake Motor - Hih Efficiency Full Locked Locked Breakdown Allowable 460 V Output Load Inertia locked rotor Weiht Sound Service % of full load Full Torque Current J Rated Torque Torque time (s) (lb) db(a) Factor (lb*ft (ft.lb) Tl/Tn Tb/Tn 2 ) speed Efficiency Power Factor load current HP kw Code Il/In Hot Cold (rpm) In (A) IV Pole /5T 2.93 M /5T 4.42 M /5T 5.90 J /4T 8.83 K /4T 14.8 J /5T 22.1 H /5T 29.5 H /6T 44.0 G /6T 58.9 G /6T 73.6 F /6T 88.3 F /6T 117 G /6T 146 F /5T 176 G /5TS 176 G /5T 220 G /5TS 220 G Hih-Output Desin T 2.93 M T 2.93 M T 4.42 M T 5.90 J T 8.83 K T 8.83 K T 14.8 J T 14.8 H /5T 14.8 H T 14.8 H T 22.1 H T 22.1 H T 29.5 H T 29.4 G /6T 29.4 G T 29.4 G T 44.0 G T 44.0 G T 58.9 G T 58.9 G TS 58.9 G /6T 58.9 G T 73.6 F TS 73.6 F T 73.6 F /6TS 73.6 F T 88.3 F /6TS 88.3 F T 117 G TS 117 G T 117 G TS 117 G T 146 F TS 146 F /5T 146 F /5TS 146 F T 176 G /6T 176 G /6TS 176 G W22 Brake Motor

15 W22 Brake Motor - Hih Efficiency Full Locked Locked Breakdown Allowable 460 V Output Load Inertia locked rotor Weiht Sound Service % of full load Full Torque Current J Rated Torque Torque time (s) (lb) db(a) Factor (lb*ft (ft.lb) Tl/Tn Tb/Tn 2 ) speed Efficiency Power Factor load current HP kw Code Il/In Hot Cold (rpm) In (A) VI Pole /5T 4.51 J /4T 6.70 J /4T 8.93 J /5T 13.3 H /5T 22.2 J /6T 33.1 G /6T 44.3 G /6T 66.1 G /6T 88.2 G /6T 110 F /6T 132 F /5T 176 G /5T 220 G /5TS 220 G Hih-Output Desin T 4.51 J T 6.70 J T 6.70 J T 8.93 J T 13.3 H T 13.3 H T 22.2 J T 33.1 G T 33.1 G T 44.3 G T 44.3 G T 66.1 G TS 66.1 G T 66.1 G /6TS 66.1 G T 88.2 G /6TS 88.2 G T 110 F TS 110 F TS 110 F TS 132 F /5TS 176 G W22 Brake Motor 15

16 Performance Data W22 Brake Motor - Hih Efficiency Full Locked Locked Breakdown Allowable 460 V Output Load Inertia locked rotor Weiht Sound Service % of full load Full Torque Current J Rated Torque Torque time (s) (lb) db(a) Factor (lb*ft (ft.lb) Tl/Tn Tb/Tn 2 ) speed Efficiency Power Factor load current HP kw Code Il/In Hot Cold (rpm) In (A) VIII Pole /4T 6.02 K /4T 8.98 H /5T 11.9 L /5T 18.0 K /6T 29.4 H /6T 44.2 H /6T 58.9 G /6T 88.3 G /6T 118 G /6T 147 G /5T 177 G /5T 235 G Hih-Output Desin T 6.02 K T 6.02 K T 8.98 H T 11.9 L T 11.9 L T 18.0 K T 29.4 H T 29.4 H T 44.2 H T 58.9 G TS 58.9 G T 58.9 G T 88.3 G /6TS 88.3 G T 118 G TS 118 G TS 118 G T 147 G TS 147 G /5TS 177 G /5TS 235 G W22 Brake Motor

17 W22 Brake Motor - NEMA Premium Efficiency Full Locked Locked Breakdown Allowable 460 V Output Load Inertia locked rotor Weiht Sound Service % of full load Full Torque Current J Rated Torque Torque time (s) (lb) db(a) Factor (lb*ft (ft.lb) Tl/Tn Tb/Tn 2 ) speed Efficiency Power Factor load current HP kw Code Il/In Hot Cold (rpm) In (A) II Pole /5T 1.48 L /5T 2.23 L /5T 2.98 L /4T 4.43 K /4T 7.40 H /5T 11.0 H /5T 14.7 H /6T 22.0 G /6T 29.4 G /6TS 36.6 G /6TS 44.0 G Hih-Output Desin T 1.48 L T 2.23 L T 2.23 L T 2.98 L T 2.94 L /5T 4.49 J T 4.49 J T 4.43 K T 4.43 K T 7.40 H /4T 11.1 J T 11.1 J T 11.0 H T 11.0 H T 14.7 H /5T 22.1 H T 22.1 H T 22.0 G T 22.0 G T 29.4 G TS 36.6 G /6T 36.6 G TS 44.0 G /6T 44.0 G W22 Brake Motor 17

18 Performance Data W22 Brake Motor - NEMA Premium Efficiency Full Locked Locked Breakdown Allowable 460 V Output Load Inertia locked rotor Weiht Sound Service % of full load Full Torque Current J Rated Torque Torque time (s) (lb) db(a) Factor (lb*ft (ft.lb) Tl/Tn Tb/Tn 2 ) speed Efficiency Power Factor load current HP kw Code Il/In Hot Cold (rpm) In (A) IV Pole /5T 2.94 L /5T 4.43 K /5T 5.92 K /4T 8.83 K /4T 14.8 J /5T 29.4 H /6T 44.0 G /6T 58.7 G /6T 73.4 G /6T 88.1 G /6T 117 G /6T 146 G /5T 175 G /5T 219 G Hih-Output Desin T 2.94 L T 2.94 L T 4.43 K T 5.92 K T 8.83 K T 8.83 K T 14.8 J T 14.7 J T 29.4 H T 44.0 G T 44.0 G T 58.7 G T 58.7 G TS 58.7 G /6T 58.7 G T 73.4 G TS 73.4 G T 73.4 G /6TS 73.4 G T 88.1 G T 87.6 G TS 87.6 G /6TS 88.1 G T 117 G TS 117 G T 117 G TS 117 G T 146 G TS 146 G /5TS 175 G W22 Brake Motor

19 W22 Brake Motor - NEMA Premium Efficiency Full Locked Locked Breakdown Allowable 460 V Output Load Inertia locked rotor Weiht Sound Service % of full load Full Torque Current J Rated Torque Torque time (s) (lb) db(a) Factor (lb*ft (ft.lb) Tl/Tn Tb/Tn 2 ) speed Efficiency Power Factor load current HP kw Code Il/In Hot Cold (rpm) In (A) VI Pole /5T 4.51 K /4T 6.67 M /4T 8.89 L /5T 13.3 K /5T 22.1 J /6T 33.1 H /6T 44.1 H /6T 66.1 H /6T 88.2 G /6T 110 G /6T 132 G /5T 176 G /5T 220 G Hih-Output Desin T 4.51 K T 6.67 M T 8.89 L T 13.3 K T 13.3 K T 22.1 J T 33.1 H T 33.1 H T 44.1 H T 44.1 H T 66.1 H TS 66.1 H T 66.1 H /6TS 66.1 H /6TS 88.2 G T 110 G TS 110 G T 110 G TS 110 G T 132 G TS 132 G /5T 132 G /5TS 132 G /5TS 176 G /5TS 220 G W22 Brake Motor 19