ari tammi, pg iec lv motors, linda stenman, lv drives, · pdf filenew revolutionary motor and...

Synchronous motor & drive packageLow Voltage motors and drives

Ari Tammi, PG IEC LV Motors, Linda Stenman, LV Drives, ABB internal training material Sep 25th 2011

Two new high-performance motor and drive packages

The High Output package� Power range from 1 to 350 kW� Powerful, yet highly compact motor with up to two frame sizes smaller than

conventional motor

For industrial applications

| Slide 2 standard motor+

special rotor

standard drive+

new software

A new revolutionary Drive Package!

conventional motor� Enables cost effective machine designs

The IE4 Super Premium Efficiency package� Power range from 11 to 200 kW� Energy losses reduced by up to 40%� Compliant to the upcoming efficiency class IE4� Payback time less than two years – from energy savings alone

Both packages are based on perfectly controlled synchronous motor technology without permanent magnets materials. Optimized for VSD operation, they combine motor, drive and advanced software into complete solutions.

9/2/2011© ABB Group

New revolutionary motor and drive package

� Similar functionality compared to traditional induction motor and drive package

� Suitable for general purpose industrial applications such as pumps, fans and compressors

� Same stator technology with induction motor combined with novel synchronous reluctance rotor

For industrial applications

with novel synchronous reluctance rotor

� Performance comparable to permanent magnet motors, but without magnets

� Optimized for VSD operation – not suitable for direct-on-line fixed speed operation

© ABB Group9/2/2011 | Slide 3

Synchronous reluctancemotorTechnology review

Synchronous reluctance technologyHistory - key technology steps

2010200519891960’s1923 19981888

(e)

© ABB Group9/2/2011 | Slide 5

(d)Iron Segment

Magnetic Barrier (Normally Air)

(No) line start capability� (a) Simple salient pole (SP) rotor

� (b) Axially laminated anisotropy (ALA) rotor

� (c) Transversally laminated anisotropy (TLA) rotor

� (d) J. K. Kostko 1923 (original patent)

� (e) Vagati and Fratta 1980s & 1990s

(c)

Synchronous Reluctance TechnologyDesign concept

Single sheet of punched electrical steel

The sheets stack to a complete rotor body. Can either be stacked on a pre-assembly piece or direct on the shaft.

© ABB BU LV Motors May, 2009 | Slide 6

on the shaft.

Mounting the rotor body on a shaft. The rotor will be balanced after shaft assembly.

The rotor body inset in a stator. A standard stator 4 pole design is used but with adapted winding.

LV motor and drive package

© ABB GroupSeptember 2, 2011 | Slide 7

Synchronous reluctance technologyFunction compared to induction motor

RRR

TS

RR

RR

S

S

TT

S

S

Induction motor Synchronous reluctance motor

© ABB Group9/2/2011 | Slide 8

RR R

T

T

S

S

ST

T

T

S

SS

T

T

TT

T

T

S

SS

S

R

R

RR

R

R

Elimination of resistive rotor losses

Key to successElimination of rotor losses

I2RRotor

Other

I2RStator

Other

IE4 SynRM motor

100%

60%

© ABB Group9/2/2011 | Slide 9

Losses

I2RStator

Other

I2RStator

Other

Traditional induction motor

IE4 SynRM motor

High Output SynRM motor

80 -90%

Product offerLV motor and drive package

Trademark and name

� High output synchronous motor and drive package

� Alumiunium motor frame M3AL 90-132 & ACS850

� Cast iron motor frame M3BL 160-315 & ACS850

� Generation code B in product code

� IE4 Super premium efficiency synchronous motor and drive

Special VSD motors

IE4 Super premium efficiency synchronous motor and drive package

� Cast iron motor frame M3BL 160-315 & ACS850

� Generation code C in product code

� Variant codes and mechanical construction details based on ”mother products” – M3AA and M3BP

� New ABB Drives product ranges support the synchronous reluctance control software. The first family with the revolutionary software is ACS850.

© ABB Group9/2/2011 | Slide 11

� Supply voltage

� 3-phase 380 V to 500 V

� Supply frequency

� 50 Hz to 60 Hz

� Motor control:

Standard ACS850 drive with new softwareNew motor control SynRM

� ABB’s Direct torque control (IM + PM + SynRM)

� Output power

� Up to 500 kW

� New variant code for synchronous reluctance motors

� +N7004 option ”SynRM”

© ABB Group9/2/2011 | Slide 12

High outputLV motor and drive package

High output range

� 90 to 132 aluminium frame, 1 to 55 kW

� 160 to 315 cast iron frame, up to 350 kW

� Up to two frame sizes smaller compared to induction motors

� Competitive product offering compared to traditional or other new technologies

’Small and powerful’

other new technologies

� Minimum IE2 efficiency

� Optimized for VSD operation up to 6000 r/min

� Simplicity – no permanent magnets

� Extended bearing service intervals

� Advanced ABB open loop control software

� Global ABB support

© ABB Group9/2/2011 | Slide 14

Super premium efficiencyLV motor and drive package

IE4 Super premium efficiency motor range

� 160 to 315 cast iron frame, 11 to 200 kW

� Energy saver – IE4 efficiency

� Replaceable with induction motors – same size and output

� Reliable – cooler bearings and windings

� Service friendly – no permanent magnets

’Simply efficient’

� Service friendly – no permanent magnets

� Optimized for VSD operation

� Advanced ABB open loop control software

� Global ABB support

© ABB Group9/2/2011 | Slide 16

Draft of the efficiency IE4 with VSD supply

VSD

SPE 160-315

Efficiency correspond to new IE4 levels (DOL)

DOL

SPE 160-315

Efficiency correspond to new IE4 levels with sinusoidal voltage

Supply Motor Efficiency level on motor

Example Efficiency level IE4 15 kW 1500rpmIEC IE4 level 94,0%

IEC IE4 level 94,0%

Conditions to describe efficiency levels for SPE range IE4

© ABB Group9/2/2011 | Slide 17

sinusoidal voltage supply

Losses and efficiency in electrical motorsEnergy facts - 37kW 1500rpm

Loss1,8 kWLosses at 95,3 % (IE4)Reduced losses = 1,1 kW

39,9 kW38,8 kW

© ABB Group9/2/2011 | Slide 18

Loss2,9 kWLosses at 92,7 % (IE2)

Savings 964 EUR per year = 4,8 tons CO2 (0,5kg/kwh)

37kW

If the efficiency level increases by 2,6 %-unit, the reduction of losses is 38%

Performance dataAvailable SynRM offering

High output range – Technical data

© ABB Group9/2/2011 | Slide 20

High output rangeTechnical data 1500rpm, M3BL160-315

© ABB Group9/2/2011 | Slide 21

High output rangeTechnical data 2100rpm, M3BL160-280

© ABB Group9/2/2011 | Slide 22

High output rangeTechnical data 3000rpm, M3BL160-250

© ABB Group9/2/2011 | Slide 23

Technical dataSynRM motor continuous loadability curve

0,8

0,9

1

1,1

© ABB Group9/2/2011 | Slide 24

0,4

0,5

0,6

0,7

0 0,2 0,4 0,6 0,8 1 1,2 1,4

T/Tn

n/nn

T/Tn IC411

T/Tn IC416

High output range SynRM vs IM

������������� ����������� ��� �������� ������������������� ����������

���� ������������������

� ���� ��!�

�� ���� � �� ���� ����

� �� � ������� ���� �� ��� ��������������� ��

�� �� � �������� ���� �� ��� ��������������� ��

�� �� � �������� ���� �� ��� ��������������� ��

© ABB Group9/2/2011 | Slide 25

� Select SynRM packages based on actual power need rather than based on IEC power rating !

�� �� � �������� ���� �� ��� ��������������� ��

���� ������������������

� ���� ��!�

�� ���� � �� ���� ����

� �� � ������� ���� �� ��� ��������������� ��

�� �� � �������� ���� �� ��� ��������������� ��

�� �� � �������� ���� �� ��� ��������������� ��

SynRM motor performance compared to IMSynRM & IM size 160MLB

© ABB Group9/2/2011 | Slide 26

Nominal speedsSynRM 40kW 1500 - 2100 - 3000rpm

25

30

35

40

45P

ower

[kW

]

© ABB Group9/2/2011 | Slide 27

0

5

10

15

20

0 500 1000 1500 2000 2500 3000 3500 4000

Pow

er [k

W]

Speed [rpm]

M3BL 200MLC 1500 r/min M3BL 160MLE 2100 r/min M3BL 160MLC 3000 r/min

Continuous and short time overloadabilitySynRM and IM

150

200

250To

rque

[Nm

]

© ABB Group9/2/2011 | Slide 28

0

50

100

0 500 1000 1500 2000 2500 3000

Torq

ue [N

m]

Speed [rpm]

IM 15kW Cont IM 15kW OL SR 18kW Cont SR 18kW OL