Motor Excellent Campaign

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Motor Excellent CampaignWhy Motor?

Using electric motors to its energy efficiency limit with excellent controls

Two thirds of the energy generation is consumed by electric motors globally, in the effort to promote a greener and energy saving environment, electric motors and their controllersmust be meticulously designed and selected to ensure the lower cost of ownership. ABB being the world leader in electric motor and motor controller manufacturing, launch this campaign to share with the audience on “Why”, “What” and “How” the design and selection the right “value for money” of motor and the con-trollers, including the starter, protection, varying the speed, etc.

We will begin with the types of motors and the characteristics, how different motors can perform differently and how the slight improve in energy efficiency can contribute to great different in total cost of ownership.

Contactor makes all the automatic switching and is a vital component for motor control; we will look into the selection of proper contactor and the protection components.

We will look into the trend of the starting solution usingelectronic means such as softstarter.

We will share with you on the best VSD that can reduce energy tremendously by varying the speed and component that educe the side effects for instance, Harmonics and EMC.

Last but not least, other important components likeprotection, monitoring and connection device to safeguard your installation against unwanted disruption.

Any cost effective solution? Yes, we have the solution!

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IE4 Super Premium Efficiency Synchronous Reluctance Motor and Drive package

IE4 Super premium efficiencyThe heart of the package is a magnet free motor meeting IE4 efficiency levels. The lowest energy bill is achieved with speed control provided by an ACS850 drive and the excellent partial load efficiency performance of SynRM technology.

Verified package efficiencyFor the first time, you don’t have to guess the combined energy consumption of the motor and drive for a given output power. The SynRM motor and drive package efficiency is measured to verify the efficiency. When comparing efficiencies between different alternatives, make sure you’re looking at efficiency values for the whole package and all the speeds that will be run.

Upgrade system efficiency withoutmechanical modificationsUnlike many other IE4 motors, most IE4 SynRMmotors follow Cenelec harmonized size and output combinations. This means that upgrading to the highest efficiency level is easy and straightforward without the need for mechanicalmodifications, keeping the payback time of the total investment very short.

Induction motor on the outside,innovation insideSynchronous reluctance motors combine innovative rotor and conventional stator technology. You get the performance of apermanent magnet motor together with the cost-efficiency,simplicity and service friendliness of an induction motor.

Full range of pre-selected packagesIE4 SynRM packages combine a matched motor and drive, and the latest software. The packages are optimized for pump and fan applications. The pre-selected packages are available from 11 to 315 kW.

Unprecedented reliabilityThe uniquely cool running rotor keeps the motor bearingtemperature very low thus increasing bearing systemreliability. Additionally, IE4 SynRM motor winding temperature rise is well below class B. These factors take motor reliability to an unprecedented level, keeping the process running without interruptions.

Based on reluctance motor technology, ABB’s super premium efficiency motor drive package meets the IE4 energy efficiency standard throughout its power range. Customers will enjoy substantial energy savings and record-shortpayback times compared to usingconventional motor and drive systems.

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Motors

ABB offers a comprehensive range of reliable and high efficiency motors andgenerators for all applications.

ABB can help every industry and application to reach new levels of efficiency and energy savings even under the most demanding conditions. Combining the best available materials with superior technology, the electric motors and generators are designed to operate reliably no matter how challenging the process orapplication, and to have low life cycle costs.

Cast iron frame− 0.25 kilowatt (kW) to 1 megawatt (MW)− IEC71-450 frame− IE2 design* Please check with our sales office for more information on IE3 and IE4 design range

Aluminium frame− 0.75 to 90 kW− IEC71-280 frame− IE2 design* Please check with our sales office for more information on IE3 design range

Hazardous area− Flameproof Ex d, Ex de IEC 71-400− Non-sparking Ex nA IEC 71-450− Increased safety motors Ex e IEC 80-400− Dust ignition Ex tD IEC 71-400

SynRM Synchronous Reluctance Motor andDrive Package− High output SynRM motor and drive packages from 17 to 350 kW for pump and fan applications.

Water Cool motors− IEC280-450 frame

Permanent magnet motors− IEC280-560 frame

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Mechanical power transmission

Belt Drives− Synchronous belt drives – full line of taper-lock, QD andminimum plain bore sprockets. Available pitches 5,8 and 14 mm

Couplings− Para-flex− Grid-lign− Disc and D Flex− Gear

GearboxesQuantis®

− ILH inline helical, RHB right angle helical bevelMSM motorized shaft mount− Output ratings, 0.75 kilowatts (kW) to 56 kW (1/4 hp to 75 hp); up to torque 14,000 Nm− Ratios, 1.5:1 - 300:1 + (capable of higher ratiosthrough tandem configuration)

Torque-Arm II− All reducers can be shaft mounted: screw conveyor vertical, and flange mounted− Horsepower ratings through 294 kW (400 hp)− Torque ratings through 56,500 Nm− Standard 5, 9, 15, 25, and up to 40:1 gear ratios

Motorised Torque Arm− Integrated gear drive with completely separatemotor adapter− Straddle mounted input pinion is supported between twobearings for maximum torque throughput− No belts or sheaves - safety and maintenance benefits− Uses standard 2 and 4 pole IEC flange mountmotors to reduce number of ratios required

MagnaGearXTR®

− Parallel shaft or right angle configurations available− Torque capacities from 32 to 104 kN-m available− Global product design to fit all markets

With Dodge mechanical power transmission products, you get more than just power.

You get the widest range of mechanical products available− plus the added assurance of a reliable partner dedicated to responsive service and complete support. For well over acentury, Dodge products have helped manufacturers and numerous industries increase the productivity and profitability of their operations.

Housed bearingsULTRA®KLEEN, E-Z KLEEN®

− Reinforced polymer and stainless steel housings− Patented polymer housing includes antimicrobial agent which resists bacterial and fungus growth− Two inserts: corrosion resistant and stainless steel insert− Three locking devices. 65° setscrew angle (SC), concentric clamp collar (D-LOK), and GRIP TIGHTadapter mount

GRIP TIGHT® ball bearings− Two types: normal duty GT and medium duty GTM− DualGuard seal - comprised of single lip seal and rubberised flinger− Thin wall adapter mounting offers 360° full shaft contact and concentricity

ISN spherical roller bearings− Industry‘s only push/pull adapter mount system− Available in two-bolt pillow blocks− Accepts commercial shaft tolerances

SLEEVOIL® RTL series hydrodynamic pillow block bearings− Extended life (no metal-to-metal contact during operation)− Handles high speeds− Dampens vibration, provides quiet operation− Fully split for ease of maintenance

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Motor control

ABB's portfolio consist of high performance blockcontactors from 9 to 2650A with a complete andharmonised 3 and 4 pole range to suit all applications together with a range of thermal and electronic overload relays and manual motor starters.

ABB offers a wide range of contactorsand contactor relays to meet todays everchanging and demanding applications.A full range of accessories for motorstarting solutions makes ABB the firstchoice for a complete solution.

The latest edition to the family is the AF range. This range of contactors from ABB uses the AF electronic coil technology allowing AC/DC control voltage with the same product. ABB also offers a range of bar contactors up to 5000A to complete the offering.

− Low energy consumption− Wide voltage range AC / DC− Voltage sag and dip immunity− Built-in surge suppressor− Possibility of direct input from Programmable Logic Controller (PLC) / Distributed Control System (DCS) systems without the need for interposing relays or contactors− Short circuit protection, type 1 and 2 coordination with manual motor starters− Large offering of accessories for direct-on-line, reversing and star-delta starters

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Softstarters

ABB's Softstarters provide integrated motor starting and monitoring functions forthe most demanding industrial situations with superior control of the current andvoltage during motor start-up and stop.

Several state-of-the-art design features make it is possible to start and stop motors smoothly while keeping mechanical and electrical stresses to a minimum. The ABB portfolio consists of three ranges, making it possible to find a suitable solution for almost all possible applications and motor sizes up to 1810 A.

PSR - the compact range− Built in by-pass, saving energy and reducinginstallation time− Sophisticated algorithm eliminating DC-component and thereby providing excellent starting performance− System concept with manual motor starters− Few setting− Optional FieldBus communication

PSE - the efficient range− Built in by-pass, saving energy and reducinginstallation time− Coated circuit boards for reliable operation inharsh environment− Sophisticated algorithm eliminating DC-component and thereby providing excellent starting performance− User friendly Human Machine Interface withilluminated display− Torque control− Kick-start− Motor overload and underload protection− Settable current limit function− Thyristor over temperature protection− Analog output− Optional FieldBus communication

PST(B) - the advanced range− Built in by-pass on larger sizes, saving energy and reducing installation time− Coated circuit boards for reliable operation in harshenvironment− Both in line and inside delta connection− Full text display for easy set-up and operation− Torque control− Kick start− Dual motor overload protection− Settable current limit function− Thyristor over temperature protection− PTC input for motor protection− Programmable output signal relays− Programmable warning functions− Event log with time stamp− Flexible analog output− FieldBus communication

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The ABB low voltage AC drives product range, from 0.18 to 5600 kW, is the widest selection available from any manufacturer. These drives establish the global benchmark signifying reliability, simplicity, flexibility and ingenuity throughout the entire life cycle of the drive.

AC drivesABB micro drives– Power range 0.37 kilowatt (kW) to 2.2 kW (1-phase)− Power range 0.37 kW to 4 kW (3-phase)− IP20 Enclosure, optional NEMA 1 kit− Built-in EMC filter− FlashDrop tool for fast drive commissioning

ABB machinery drives− Power range 0.37 kW to 2.2 kW (1-phase)− Power range 0.37 kw to 500 kW (3-phase)− IP66, IP67 of IP96K as optional variant up to 7.5 kW− DTC (direct torque control)− Designed for reliability− Advanced energy savings− Remote monitoring and diagnostics− Optional I/O extensions− Master-follower

ABB water drives− Power range 0.37 kW to 400 kW (3-phase)− DTC (direct torque control)− Maintenance assistant− Rapid and simple pumping system start-up− Protection against incorrect wiring− Energy savings up to 50%− Pump cleaning or anti-jam control− Optimal pump control for various applications− Easy and cost effective cabinet assembly− Remote monitoring and diagnostics

ABB HVAC drives− Power range 0.75 kW to 355 kW (3-phase)− Fire mode operation (override mode) − Commissioning & Maintenance assistants− Real time clock and calendar− BACnet MS/TP, N2, FLN and Modbus embedded− Reduced Total Harmonic Distortion (THD)

Motion control products− Power range 1.5 A to 210 A (1-phase and 3-phase)− Real time Ethernet motion bus systems− Multi-axis coordination motion

ABB Industrial drives ABB standard drives. ACS800

− Power range 0.55 kW to 5600 kW (3 phase)− DTC (Direct Torque Control)− Marine approved (ABS, DNV, GL, RINA, Lloyd’s Register)− Available in both Air−cooled & Liquid−cooled solution− Adaptive programming− Versatile braking options− Available Ultra−low harmonic drives (THD(i) <5%)− Available Regenerative drives − Worldwide approval (CE, UL, cUL, CSA, C−Tick, GOST R)− Safe torque off− Dedicated application know-how software − Compact and modular design

DrivesLow voltage AC and DC drives

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Manual Motor Starter

ABB offers a complete standard motor-protection concept for the world market. Man-ual motor starters are protection devices for electrical installations and motor applica-tions

These devices are mainly used to switch motors manually on/off and protect them against short-circuit, overload and phase failures. Fuse less protection with a manual motor starter saves cost, space and ensures a quick reaction under short-circuit condition, by switching off the motor within milliseconds.

Customer benefits

– Compact design / space saving– Various functions in one device– Quick reaction / fast current limitation– Motor protection concept for the world market (IEC, UL)– Safe and cost-saving solution

Protection functionalities

– Overload– Short-circuit– Phase loss sensitivity

Features

– Manual control– Disconnect function– Handle can be locked in the off position– Remote control via undervoltage release or shunt trip– Trip indication– Temperature compensation– Adjustable current setting

Products for a complete ABB offer

– Shot-circuit breaking capacity up to 100 kA– Magnetic-only starters in modular DIN rail design– Special version for transformer protection– Full range of accessories– System solutions

Further benefits

– Handle in the middle position after tripping– clear and reliable indication of fault in the event if short–circuit tripping

– Handle can be locked directly in the off position

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Thermal Overload Relays

Thermal overload relays are economic electromechanical protection devices for the main circuit. They offer reliable protection for motors in the event of overload or phase failure. Starter combinations are setup together with block contactors and mini contactors.

The thermal overload relays are three pole relays with bimetal tripping elements. The motor current flows through the bimetal tripping elements and heats them directly and indirectly. In case of an overload (over current), the bimetal elements bent as a result of the heating. This leads to a release of the relay and a change of the contacts switching position (95-96 / 97-98).

Characteristics of thermal overload relays: TF range

– Trip class 10– Ambient air temperature – operation: –25°C … +60°C– Sealable cover for operating elements

Characteristics of thermal overload relays: T16 range

– Trip class 10– Ambient air temperature – operation: –25°C … +60°C

General characteristics of thermal overload relays

– Manual or automatic reset selectable– Trip-free mechanism– Phase loss sensitivity– 2 electrically isolated auxiliary contacts– Test and STOP function– Trip indication on the front– Temperature compensation– Useable for AC or DC application– Suitable for three and single phase applications– All phase are equipped with bimetal tripping elements– All terminal screws are accessible from the front

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Universal Motor Controller UMC100-FBP

Large industrial plants often contain several thousand motors in order to provide the necessary motion. Any unplanned or sudden motor stops can lead to faults in theprocess sequence, which can be a very cost-intensive matter. For this reason,reliable management of these motors is decisive for ensuring a controlled production sequence.

ABB’s UMC100-FBP offers you the optimal solution. UMC100-FBP is a flexible, modular and expandable motor management system for constant-speed low-voltage range motors. Its most important tasks include motor control and protection, prevention of plantstandstills and the reduction of down time. This is made possible by early information relating to possible motor problems which enables unscheduled plant standstills to be avoided. Even if a motor trips, quick diagnosis of the cause of the fault serves to reduce downtime.

Main features of the UMC100-FBP

– Comprehensive electronic motor protection detectingovercurrent, undercurrent, phase failures, unbalance, blocking, earth leakages, phase sequence, phase imbalance, earth fault and more– Overload and underload protection based on active power– Limitation of the number of starts within a given period– Earth fault protection– Integration of the most important control functions as ready, easily parametrizable blocks– Load shedding and restart logic built in

– Freely programmable for special, application specific control functions– Quick and comprehensive access to all data via LCD panel, fieldbus and/or laptop– Optional fieldbus interface for Profibus DP, DeviceNet,CANopen, Modbus RTU, & Modbus TCP– Graphics enabled display with backlit– Multifunctional expansion modules with 8 digital inputs, 4 relay outpus and 1 analogue output– ATEX approval for use with motors in EEx areas

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Electronic Products and Relays

With the product line Electronic Products and Relays ABB offers a wide range andassortment of products for switchgear and control gear for the electrical equipment and automation of machinery and plants.

The versatile products offer a maximum of security, economic efficiency and capacity. This, they contribute considerably toincrease your added value and meet the requirements of you and your customer. Constant further development of ourproduct range always makes new application possible. The range covers products from analog signal converter up tomeasuring and monitoring relays and time relays.Easy-to-set front-face operating controls and clearly labeled connecting terminals provide high ease of use and easyhandling, making wiring and commissioning quick and simple. The compact dimensions save space in the distribution panels and therefore save money.

Electronic Timers

For many years, ABB’s CT range electronic timers have been used in applications worldwide and has proven its excellent functionality in daily use even under the toughest conditions.

The CT range includes 103 electronic timers and switchingrelays with 16 different functions. The electronic timers are divided into three ranges with their individual benefits. A lot of different connection terminals such as screw, chamber, double-chamber cage and push-in connection terminals are available. Furthermore, relay outputs and solid-state outputs are also available.

Three Phase Monitoring Relays

Only highly and continuous monitoring of a three-phase network guarantees the trouble-free and economic operation of machines and installations. Thus, the important parameters to monitor three-phase systems are:

– Phase voltages– Phase sequence– Phase unbalance– Phase loss– Frequency

Thermistor Motor Protection Relays

The thermistor motor protection relays are used to control motors equipped with PTC temperature sensors. The PTC temperature sensors are incorporated in the motor wndings to measure the motor heating. This enable direct control and evaluation of various operating conditions. Depending on the products also ATEX approvals for use in hazardous areas are available.

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Arc Guard System™ – TVOC-2A flexible and intelligent solution for you and your business safety.

ABB is leader in arc guard technology since 35 years.Experience from the highly appreciated TVOC is built into the new TVOC-2, a product for protection of humans and property when having an electric arc. With TVOC-2, we set an entirely new standard.

HMI (Human Machine Interface)

As reliable and simple as the previous Arc Guard system,TVOC-2 is introduced with additional and improvedfeatures and functions. To meet the demands of our customersand end-users, it focuses on Reliability, Flexibility and Simplicity.Furthermore, with its functional safety (SIL 2) design, TVOC-2is approved for today’s applications as well as tomorrow’sindustry needs.

Reliability

Certified according to functional safety (SIL 2) standard.

Over 35 years of experience in Arc Guard Systems.

Pre-calibrated optical sensors.

Flexibility

HMI can be mounted on the panel-door.

Expand with up to 30 optical sensors.

Configure the system according to various needs.

Simplicity

User-friendly start-up menu.

DIN-Rail or wall-mounted.

Easy to expand as the switchgear grows.

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Safety

ABB Jokab Safety is one of only a few manufacturers offeringa complete safety system. This enables users to design acomplete Australian Certified safety system from the sensorto the fencing system, offering the highest level of protectionfor both man and machine.

For proven competence in development, design andstandards in the Australian machine safety arena, ABB JokabSafety offers a safety solution for the majority of industrialapplications.

Functional safety technology

− Jakob safety sensors, actuators, safety relays andprogrammable safety controllers− Safety PLC and safe F/O systems built on PROFISafe− Integrated drive safety functions

The ABB Jokab Safety product offering is a complete range of safety products, from category 4 dual safety circuit safety relays, light curtains, sensors andswitches to bumpers, mats and fencing systems.

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SNK series, terminal blocksScrew clamp technology

Rely on our expertise

ABB screw clamp technology benefitsfrom 50 years of experience.Billions of our screw clamps have beenmanufactured and are used worldwideevery day.

Qualified for worldwide markets and applicationsEco-designed according to international environmentalstandards in sustainable development.

A smart design to support your daily connection challenges

Revitalise your electrical installationsModern. High quality finishing.

Improve marking visibility from any directionAsymmetrical design offers the best visibility from anydirection, +20% marking surface.

Facilitate your rail assembly processAsymmetrical shape: easy to handle, prevents risk of shortcircuit.Stiffness: improved holding adherence to the rail, lowdeflection when tightening. Locking pin: quick and easy tolock up to ten blocks in position at a time.

Smooth your connecting processEngineered conductor entry: optimized conductor guiding,easier connection. One or two conductors. Conductors withor without ferrules.

Facilitate maintenance operationsTerminals can be individually removed from a terminalassembly equipped with markers: ABB markers becomeindependent after strip mounting, ABB markers remain onterminal in any situation. Handwriting possible.

ABB Pte. Ltd.2 Ayer Rajah CrescentSingapore 139935Tel: +65 6776 5711Fax: +65 6778 0222

www.abb.com.sg

Contact centerPhone: +65 6222 7778E-mail: lp.marketing@sg.abb.com

© Copyright 2014 ABB. All rights reserved.Specifications subject to change without notice.