Baldor Adjustable Speed Direct Drive Cooling Tower Motor and Drive System
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Adjustable Speed Direct Drive Cooling Tower System
New Direct Drive Technology – Improves Reliability, Reduces Maintenance, Runs Quieter & Saves EnergyBycombiningthetechnologiesofthefieldprovenandpowerdenseAClaminatedframeRPMACmotorwithhighperformancepermanentmagnet(PM)salientpolerotordesignsandthematchedperformanceofanadjustablespeeddrive,BaldorElectriccanofferhightorquedirectdrivemotorsforcoolingtowerapplicationswithallthebenefitsofvariablespeedcontrolandeliminatingthecostandmaintenancerequiredfortraditionalgearboxorbeltedsolutions.ThefancouplesdirectlytothemotorandiscontrolledbyauniqueACdrivetoprovideoptimalspeedandcoolingtowerperformancethatrunsquieterwithreducedenergyconsumption.ThedriveisdesignedtoaccommodatethemostcommonHVACcommunicationprotocols.
Direct Drive RPM AC Synchronous PM Motor Reduces Maintenance CostTheRPMAC™synchronousPMmotoruseslaminatedfinnedframeconstructiontoprovideahighlyefficientpowerdensepackagewithflangemountingdimensionsthatcanreplacetherightanglegearboxandjackshaftinstallationinmanyconventionalcoolingtowers.Thissametechnologyisofferedinconventional,yetpowerdense,footmounteddesignsthatcanreplacethebeltandsheaveapplicationwheremoreverticalmountingspaceisavailable.Derivedfromoneofthetoughestmotorplatformsusedinthemostdemandingindustrialapplications,theRPMACmotoristherightsolutionforoperationinsidethetower’shotandhumidenvironment.TheTEAO(totallyenclosedairover)RPMACcoolingtowermotorisdesignedforminimalmaintenance.Bearingsrequirelubricationonlyonceperyear.WateringressalongtheshaftispreventedwiththeuseofanInpro/Seal®bearingisolatorandaslinger.TheelectricalinsulationsystemismanufacturedusingaVPI(vacuumpressureimpregnation)processthatensureslongmotorlifeeveninthemostextremeenvironmentalconditions.Condensationdrainsrelieveanymoisturethatmaycollectinsidethemotor.Nomorechanginggearoil,lubricatingpillowblockbearingsorchangingoutbelts.
Baldor VS1CTD PM Cooling Tower DriveTheBaldorVS1CTDintegratescustomfeaturesthathavebeendesignedexclusivelyforthecoolingtowerindustry.TheVS1CTDutilizesourMatchedPerformancephilosophytopaireachRPMACPMmotorwithaspecificcontrol.CriticalmotoroperationalparametersareintegratedrightintotheVS1CTDfirmwaretoprovidesimplifiedCoolingTowerstartups,eliminatingtheneedforuserstoentercomplexinformationintothecontrolortheneedtotunethecontroltothemotorpriortooperation.SincetheVS1CTDistargetedforuseinthecoolingtowermarket,muchofthecomplexitythattypicallyresidesingeneralpurposecontrolshasbeeneliminatedfurtheraddingtothesimplicityofourAdjustableSpeedDirectDriveCoolingTowerMotorandDriveSystem.
Whensystemautomationandcontrolisarequirementforyourcoolingtoweroperation,theBaldordrivereadilycommunicateswithmultiplecommunicationnetworksincludingMODBUS-RTU,MODBUS/TCP,LonWorks,Metasys-N2,BACnet,EtherNet/IP,DeviceNetandPROFIBUS.
Field Tested ReliabilityAfterextensiveLabtestingatBaldor’sfacility,motoranddrivesystemshavebeeninstalledandfieldtestedforaslongasthreeyears.OnesystemisrunningunderacontrolledenvironmentononeoftwoidenticalcoolingtowersatClemsonUniversity.BothtowerswereinstrumentedandthetraditionalgearedsystemwascomparedtotheoneconvertedtouseBaldor’sAdjustableSpeedDirectDriveMotorandDriveSystem.Eachtowerhadthesame5blade18footdiameterfan.Theconversionwasmadeinlessthanaday.Performanceresults,whichwereverifiedbyathirdparty,measuredaninputkWpowersavingsof11.8%comparedtoatraditionalgearedsystem,withhighspeednoisereductionfrom82.3dBAto74.4dBAandreducedvibration.
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RPM AC Direct Drive Cooling Tower Features & Benefits
Direct Drive Motor •Eliminatestheneedforagearbox,jackshaft,pillowblockbearingsandcouplings •Reducesmaintenanceandprovidesimprovedreliability •Eliminatescoolingwatercontaminationbyeliminatinggearboxoilandleakage •Reducespowerconsumption •Resultsinincreasedsafetybecausetherearefewermechanicalcomponents •Water-tightmotordesignoperatesintheairstream •Eliminatesthealignmentofmechanicalcomponentsforquickerinstallationandreducedinstallationcosts
Bearings and Seals •OversizedtomaintainlongerbearinglifeexceedingL-10100,000hours •Greaselubricatedforlonglife •Handlesfanloadswithimprovedreliability •ProvenInpro/Seal®bearingisolatorwithslingerumbrellaoverseal •Onlyoneingresspoint •InsulatedoppositedriveendbearingonFL440andFL5800
Adjustable Speed Control •DesignedspecificallyfortheCoolingTowerIndustryandcanbesetattheoptimumspeedpoint •SensorlessPermanentMagnetmotorcontroloperateswithoutanencoderorresolver •Trickleheatingeliminatesneedformotorspaceheaters •NotuningisrequiredduetotheMatchedPerformanceofthemotorandcontrol •Allowsforasoftstart(controlledramp) •Savesenergyandreducesmechanicalstressonthesystem •Improvessystemreliabilityandextendslife •Reducesnoise •Allowsforoptimizedreturnwatercoolingtemperatureforoptimizedcompressoroperation •Tricklecurrentforbrakingpreventsfanwindmillingwhennotinoperation •Systemresonancespeedscanbebypassed
Communication Protocols •UtilizesMODBUS-RTU,MODBUS/TCP,EtherNet/IP,LonWorks,Metasys-N2,BACnet,DeviceNetorPROFIBUSprotocols •Interfaceswithexistingbuildingautomationsystems
MATCHED
PE
RF O R M A N C E
®
Retrofit or New Tower DesignsRPMACcoolingtowermotorsareavailableineitherflangemountorfootmountdesignsformountingintheairstream.Theflangemountunitsaredesignedtobeinterchangeablewithmanypopulargearboxboltholemountingconfigurations.Shaftheight,diameterandflangemountingdimensionscanbedirectlyinterchangeablewithsomeexistingcoolingtowergearboxdesigns.Highermotortorqueratingsareavailableusingtallermotorswhenspaceisavailable.Inaddition,traditionalfootmountconstructionisavailable.BothflangeandfootmountdesignsareavailableinawidetorquerangeinframesizesFL250,FL280,FL440andFL5800.
A typical conventional fan drive arrangement of a gearbox mounted under the fan.
Baldor’s Direct Drive motor eliminates many components of a right angle geared system.
Conventional Tower Design New Direct Drive Tower Design
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RPM AC Cooling Tower Motor and Drive Specifications
Motor
Motor Frame Size
Max. Torque (lb. ft.)
Min. Re-quired Air Velocity (ft/min)
Aprox. Wgt. (lb)
*Est. Motor Height
“M” (in.)
Catalog Number
FL2554 90
500
375 15 Custom
FL2562 155 440 17 Custom
FL2570 215 515 19 Custom
FL2578 290 590 21 Custom
FL2873 305
750
610 19 Custom
FL2882 415 705 21 Custom
FL2890 510 790 23 Custom
FL2898 590 860 25 Custom
FL4472 500
750
1154 18 Custom
FL4477 720 1290 19 Custom
FL4485 1050 1515 21 Custom
FL4493 1375 1730 23 Custom
FL4402 1820 1980 25 Custom
FL4413 1275 2290 28 Custom
FL4421 2740 2510 30 Custom
FL4429 3050 2730 32 Custom
FL4440 3520 3035 35 Custom
FL5816 4744
750
5445 37 Custom
FL5818 5400 5880 39 Custom
FL5820 6058 6315 41 Custom
FL5822 6715 6750 43 Custom
FL5824 7372 7185 45 Custom
FL5826 8029 7620 47 Custom
FL5828 8686 8055 49 Custom
FL5830 9343 8490 51 Custom
FL5832 10000 8925 53 Custom
Selectmotorframesizeasdeterminedbyrequiredfantorque.FanTorque=(HP*5252)/FanSpeed.UseexistingmotorHPandfanspeedtocalculaterequiredtorque.
DriveMax. Amps HP Frame Catalog
Number
240 Vac
19.4 5 AA VS1CTD25-1B
19.4 7.5 AA VS1CTD27-1B
37.0 10 B VS1CTD210-1B
47.5 15 B VS1CTD215-1B
59.8 20 B VS1CTD220-1B
70.4 25 C VS1CTD225-1B
91.5 30 C VS1CTD230-1B
91.5 40 C VS1CTD240-1B
147.5 50 D VS1CTD250-1B
147.5 60 D VS1CTD260-1B
480Vac
11.9 10 AA VS1CTD410-1B
23.0 15 B VS1CTD415-1B
28.9 20 B VS1CTD420-1B
34.0 25 B VS1CTD425-1B
44.2 30 C VS1CTD430-1B
55.3 40 C VS1CTD440-1B
65.5 50 C VS1CTD450-1B
90.8 60 D VS1CTD460-1B
116.6 75 D VS1CTD475-1B
136.3 100 D VS1CTD4100-1B
143.8 125 D VS1CTD4125-1B
204.0 150 E VS1CTD4150-1T
256.7 200 E VS1CTD4200-1T
600Vac
9.4 10 AA VS1CTD510-1B
18.7 15 B VS1CTD515-1B
23.0 20 B VS1CTD520-1B
27.2 25 B VS1CTD525-1B
33.6 30 C VS1CTD530-1B
42.6 40 C VS1CTD540-1B
50.8 50 C VS1CTD550-1B
72.8 60 D VS1CTD560-1B
93.1 75 D VS1CTD575-1B
117.5 100 D VS1CTD5100-1B
132.8 125 D VS1CTD5125-1B
173.6 150 E VS1CTD5150-1T
218.8 200 E VS1CTD5200-1T
Selectdrivebaseduponmotorfullloadamps.ForlineandloadreactorsseetheBaldor501catalog.
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RPM AC Cooling Tower Motor DimensionsSelectmotorframesizebaseduponrequiredfantorque
Min.
Max.
4 holes on“X” B.C.
4 holes on“Y” B.C.
ShaftLength
UsableShaft
Length
Length“M”
“U” Diam.
FL Family
Motor Frame Size
* Typical Shaft Length
Usable Shaft Length
* Typical Shaft Dia. “U”
“X” Min.Bolt Circle (in.)
“Y” Max.Bolt Circle (in.)
Number of holes per bolt
circle
FL25XX 8.5 6.94 1.999 14 16 4
FL28XX 8.0,8.5 5.75,6.25 2.374 15-16Slot 20 4
FL44XX 8.5,9.0,9.5 6.38,6.88,7.38 2.999 22 25 4
FL58XX 12.0 6.88,11.75 4.999 – 34 8*Shaftlengthanddiametercanvarybyapplicationrequirements.Taperedshaftsarealsoavailable.Typicaltaperis1/2”perfoot.Specialnon-standardshaftrequirementsmustbedefinedontheorder.
Motor Features• Mountingpadforvibrationsensor• Thermostatsoneperphasenormallyclosed• Heavybuildexternalcoatings• ProvenInpro/Seal®bearingisolatorwithslingerumbrellaoverseal• Proveninsulationsystemtechnologyusedinoff-shore drillingapplications
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Adjustable Speed Drive Cooling Tower DimensionsSelectdriveratingandframesizebaseduponmotorfullloadamps
Dim n es (mm) ensio s inch
gnitn ediOig
uts MouWe ht
Size
Height W h (B D Wi 1) (k(A) idt ) epth (C) Height (A1) dth (B lb g)
AA 12.27 (3 202 8. 8) 5 (2 7. ) 11) 7. (97 ) 21 (20 11.7 98) 38 (187 20 (9.1)
B 18.00 (4 31 9. 5 (4 7.00 (178) (157) 9.10 (2 ) 75 (248) 17.2 38) 30 3.6)
C 22.00 (5 231 9. 5 (5 7.00 (178) (259) 9.10 ( ) 75 (248) 21.2 40) 60 7.2)
D 28.00 (7 1 (292 13. 30) 25 (6 9.50 (241) 0 (511) 1.50 ) 00 (3 27. 92) 12 4.4)
E 42.81 (1 1 (47 16. 07) 75 (1087) 8.75 6) 05 (4 39. 010) 15. (175 (400) 250 13.4)
0.25(6.35)dia.
Exhaust
0.25(6.35) dia.
B1
A1
A
B1
A1
A
0.35 (8.9)
B C
0.35(8.9) Exhaust
B C
# HolesSize
AA 4 0.870 (22)
Diameterinches (mm)
# Holes Diameterinches (mm)Size
B
C
D
33333211
1.115 (28.3)1.362 (34.6)
1.680 (42)
2.470 (62.7)1.362 (34.60.500 (12.7)
E
1.115 (28.3)
1.115 (28.3)
1.115 (28.3)4.000 (102)1.680 (43)0.500 (12.7)
3211
Size AA
Sizes B, C, D and E
FrameSize
Dimensions inches (mm)Weightlb (kg)Outside Mounting
Height (A) Width (B) Depth (C) Height (A1) Width (B)
AA 12.27(311) 7.97(202) 8.21(208) 11.75(298) 7.38(187) 20(9.1)
B 18(457) 9.10(231) 9.75(248) 17.25(438) 7.00(178) 30(13.6)
C 22(559) 9.10(231) 9.75(248) 21.25(540) 7.00(178) 60(27.2)
D 28(711) 11.50(292) 13.00(330) 27.25(692) 9.50(241) 120(54.4)
E 42.81(1087) 18.75(476) 16.06(407) 39.75(1010) 15.75(400) 250(113.4)
CustomenclosuresincludingNEMA4Xareavilable
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Easy Field InstallationBelowisamotorfanassemblybeingloweredintoposition.
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Baldor Cooling Tower Motor RFQCompany Name: Project:
Fan Diameter (ft.) ____________________________ Air Flow (cfm) ___________________________
Fan Speed (RPM) ____________________________ Ambient Temp. __________________________
Existing Motor Hp ____________________________ Static Pressure (inches of H20) _______________
Fan Shaft Hp ____________________________ ___ Air Density (lb/ft3) ________________________(This is normally an odd number ex: 42.3 Hp based on operating conditions)
Voltage Required ____________________________ Fan mfq P/N ____________________________
Height Restrictions_________YES / NO ___________ No. Fan Blades __________________________
“A” inches _________________________________ If Yes, please give maximum height from motor to mounting plate to shaft extension (see diagram - “A” dimension)
Match Existing Bolt Hole Pattern?____YES / NO _____
If Yes, please give existing Bolt Hole Pattern ________________________________________________
Air Velocity in Region of Motor (ft/min) _____________________________________________________(shaded area shown below)
If retrofit…
Gearbox Manufacturer_______________________________
Gearbox Model No.__________________________________
The Baldor Solution requires a Baldor CTPM VFD
Approximate distance from motor to VFD location _______ Feet
Drive location: Control Room __________ Outside: __________
Fan Shaft Diameter (in.) Keyway (in.)
1.999” ± .0005” 1/2” x 1/4”
2.374” ± .0005” 5/8” x 5/16”
2.624” ± .0005” 5/8” x 5/16”
2.999” ± .0005” 3/4” x 3/8”
Other Shaft Dia. Requirements
Required information to quote properlyQuestions regarding above information Please contact your local Baldor District Office
6”fromMotor/Gearbox
AirFlow “A”Small end dia “B” _________________________Large end dia “C” _________________________Length of taper “L1” _______________________Length of exposed shaft “L2”_________________Keyway size “F” __________________________Shaft end drilled & tapped hole “D” ____________
B
C
D
L1
L2
F
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Energy Ef�cient Premium Ef�ciency® PM
% E
FFIC
IEN
CY
0 20 40 60 80 100 120
% LOAD
AnotherimportantaspectofthePMmotordesignversusatraditionalinductionmotorisitsabilitytomaintainhighefficiencyperformancewhenoperatingunderlowloadconditionswhicharetypicalforvariablespeedfanapplications.
V*S Control Provides Optimized Cooling Tower Performance and Energy Savings Even Under Low Load ConditionsByoptimizingmotorspeedconsiderableenergycanbesaved.Theentirecoolingtowersystemmustbedesignedforthe“WorstCase”(orhighestairflow)scenario.Foroptimumsystemperformancethefanmayneedtooperateatreducedspeed.
Asthespeedofthemotorisdecreased,theairflowdropsinacorrespondinglinearfashion.So,forexample,ifthemotorrunsatonly50%speed,theairflowiscorrespondinglyreducedto50%ofmaximumairflow.However,theinputpowertothemotorvarieswiththecubeofthemotorspeed.Forexample,ifamotorisrunathalf-speed,thepowerconsumedbythemotoris12.5%or1/8[i.e.(½)3]ofthepowerconsumedatfullspeed.So,iftheneededairflowcanbeachievedbyrunningathalf-speed,itispossibletosavealargeamountofenergy(seeenergychartbelow).
Adjustable Speed Saves Energy
Permanent Magnet Maintain Efficiency Over Wide Load Range
0 20 40 60 80 100
100
80
60
40
20
0
% RPM
% In
put
Pow
er
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Why Baldor?
Fornearly100years,Baldorhasstrivedtoprovidecustomerswiththebestvalueandreliabilityinindustrialelectricmotors.ThatdedicationshowsincustomerpreferenceforBaldor•Reliancemotors.Tobeconsideredasthemostpreferred...
Baldor offers the industry’s broadest line of stock products. SavevaluabletimewithjustonecalltoBaldor.Weoffermorethan10,000stockmotors,drives,gearboxes,bearingsandPTcomponents.
Energy-efficiency leader. Baldorbeganloweringtheenergyconsumptionofourmotorsinthe1920’s,longbeforeotherswereeventalkingaboutit.Today,Baldor’sexpansivelineofPremiumEfficiencymotorsextendsfrom1through15,000Hp.Baldor’smotorsoffercustomersthehighestoverallefficiencylevelsintheindustry,includingBaldor•RelianceSuper-E®(1through500Hp)motorsthatexceedNEMAPremium®efficiencies.
Baldorcontinuallylooksforapplicationswhereimprovementsinenergyefficiencyispossible.ByreplacingconventionalcoolingtowerfandrivesystemswithBaldor’sadjustablespeeddirectdrivemotoranddrivesystem,significantimprovementsinenergyefficiencyarepossible.
Baldor products are available at more locations than any other brand. Our35districtofficesacrossNorthAmericaandofficesaroundtheworld,offerimmediateandlocalavailabilityofBaldorproductstothousandsofcustomers.
Continuous innovation to improve reliability. Baldorleadsthemotorindustryinapplyingnewtechnologiestoimprovemotorreliability.RecentimprovementstothelineofSevereDutymotorsarefurtherproofthatBaldoristheleaderinmotorsforprocessindustryapplications.Theseimprovementsareexplainedindetailinthefollowingpages.
Industry’s shortest lead times/Flexible manufacturing. Baldorhastheindustry’sshortestleadtimesoncustommotors.OuruniqueLEANFLEXFLOW™manufacturingprocessletsusproduceanyorderinanyquantity,quicklyandefficiently.
Industry’s best information. OnlyBaldorofferscustomerssomanychoicesforproductinformationwithawidevarietyofcatalogsandproductbrochures,theBaldorWebsiteatwww.baldor.com,oryoumaytalktoaBaldorcustomerservicepersonatoneofoursalesoffices.
94%2003
20%1985
50%1990
90%2000
95.5%2007
Customer Preference
The percentages shown reflect results of studies conducted in which Baldor was chosen as “most preferred”
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Leadership in Premium Efficiency Calleda“keybreakthrough”bytheConsortiumforEnergyEfficiency,theCEEin1998recognizedBaldor’sSuper-Easthefirstpremiumefficientmotorlinetomeettheirstringentefficiencycriteria,citing“Forthefirsttime,onemanufacturerwillcarryallqualifyingproducts.”
MinimumEfficiencyPerformanceStandards(MEPS)forelectricmotorsarebecomingcommonplacethroughouttheworld.ThefirstofthesewastheEnergyPolicyActof1992(EPAct)thatmandatedefficiencylevelsfor1-200HpgeneralpurposemotorsforsaleintheU.S.afterOctober1997.TheEnergyIndependenceandSecurityActof2007(EISA)buildsuponEPActandraisestheefficiencylevelforthesemotorstoNEMAPremium®efficiencyaddsotherconfigurationsand201-500HpratingsforMEPScompliance.Baldor•RelianceSuper-EmotorsmanufacturedtodaymeetorexceedEISArequirements.
Ascountriesandregionsacrosstheworldestablishminimumefficiencylevelsformotors,morecompaniesareturningtotheBaldor•RelianceSuper-E.Thisincludesplantandprocessingapplications,aswellasOEMproductsforshipmentoverseas.Super-EmotorsmeetorexceedtheefficiencylevelsdefinedbyNEMAPremium®,EPActintheU.S.,NRCinCanada.CEMEPEFF1inEurope,andthenewIE3levelofIEC60034-30.
Awideselectionofpremiumefficientmotors,availablefromstock,manufacturedandsoldbyacompanycommittedtobuildingbetterproductsforindustriesworldwide.Nowonder,sincethe1920s,Baldor•Relianceisrecognizedastheleaderinenergyefficientindustrialmotorsanddrives.
Making Energy Efficiency Work For YouWhy is Energy Efficiency Important?Electricmotor-drivensystemsusedinindustrialprocessesconsume63%ofallelectricityusedinU.S.industrialsectoraccordingtoaU.S.DepartmentofEnergyreportpublishedin1998.A2002reportshowsthatcompaniesthatpracticedDOE“bestpractices”actuallyaveraged33percentsavingsiftheyweretoapplymotorandmotorsystemefficiencyupgrades,includingtheuseofadjustablespeeddrives.Thepotentialpositiveimpactsoncompanies’bottomlinesandtheenvironmentaresignificant.
Purchase Price is Only a Small Piece of the PieThepiecharttotherightshowsthetypicallifecyclecostofa100Hpmotoroperatingincontinuousdutyovera20-yearlife.Asyoucansee,theoriginalpurchasepriceisalmostinsignificantcomparedtowhatitwillcosttopowerthemotorduringitsusefullife.
How Baldor Super-E® Efficiencies Compare to Industry StandardsBaldor’slineofSuper-Emotorsofferscustomersthehighestlevelofoverallefficienciesavailablefromanymotormanufacturer,meetingorexceedingNEMAPremium®efficiency.
BE$T® Baldor Energy Savings Tool Makes Calculating Payback EasyInordertomakepaybackcalculationseasierforcustomers,BaldordevelopedBE$T,BaldorEnergySavingsTool.Thesoftwarehelpscalculateenergycostandenergysavingsformotors,aswellaspaybacktimeframes.ApopularfeatureofBE$Tisthatitallowsuserstomakehead-to-headcomparisonsofuptothreemotors,givingcustomerstheinformationtomakeaninformeddecisionthroughcomparativeanalysis.
BE$T,BaldorEnergySavingsToolisavailableasadownloadthroughBaldor’saward-winningWebsite(www.baldor.com/support/software_BEST.asp,)aswellasastand-aloneCD-ROM,availablefromyourBaldorDistrictOffice.
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Electric Motor Efficiency Ratings
What is Higher Efficiency Worth?
A Baldor Super-E motor and Inverter Control provide premium energy efficiency and improved process control to a municipal water treatment facility.
© Baldor Electric CompanyBR411
Printed in U.S.A.10/10 TCP 25,000
BALDOR ELECTRIC COMPANYWorld Headquarters • P.O. Box 2400 • Fort Smith, AR 72902-2400 U.S.A.
Ph: (479) 646-4711 • Fax (479) 648-5792 • International Fax (479) 648-5895 • www.baldor.com
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