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

Synchronous motor & drive package


Low Voltage motors and drives
Two new high-performance motor and drive packages
For industrial applications

| Slide 2
standard motor standard drive A new revolutionary
+ + Drive Package!
special rotor new software
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
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.

ABB Group
9/2/2011
New revolutionary motor and drive package
For industrial applications

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
Performance comparable to permanent magnet motors, but
without magnets
Optimized for VSD operation not suitable for direct-on-
line fixed speed operation

ABB Group
9/2/2011 | Slide 3
Synchronous reluctance
motor
Technology review
Synchronous reluctance technology
History - key technology steps
1888 1923 1960s 1989 1998 2005 2010

(e)

(c)

Iron Segment (d)

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


ABB Group
9/2/2011 | Slide 5
Synchronous Reluctance Technology
Design 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.

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.

ABB BU LV Motors
May, 2009 | Slide 6
LV motor and drive package

ABB Group
September 2, 2011 | Slide 7
Synchronous reluctance technology
Function compared to induction motor

Induction motor Synchronous reluctance


motor

R
R T R
R R
R T R
S S
S T
S
S
S T
R T

S T R T

T S T R

T R
T S
S S
T S S S
R R R T
R R T
Elimination of
ABB Group
9/2/2011 | Slide 8
resistive rotor losses
Key to success
Elimination of rotor losses
60%
Other

100% I2 R
Stator
I2 R
Rotor

Other IE4 SynRM motor


80 -90%
I2 R
Stator Other

Losses
I2 R
Traditional induction motor Stator
High Output SynRM motor
ABB Group
9/2/2011 | Slide 9
Product offer
LV motor and drive package
Trademark and name
Special VSD motors

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


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 Group
9/2/2011 | Slide 11
Standard ACS850 drive with new software
New motor control SynRM

Supply voltage
3-phase 380 V to 500 V
Supply frequency
50 Hz to 60 Hz
Motor control:
ABBs Direct torque control
(IM + PM + SynRM)
Output power
Up to 500 kW
New variant code for synchronous
reluctance motors
+N7004 option SynRM

ABB Group
9/2/2011 | Slide 12
High output
LV motor and drive package
High output range
Small and powerful

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
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 Group
9/2/2011 | Slide 14
Super premium efficiency
LV motor and drive package
IE4 Super premium efficiency motor range
Simply efficient

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
Optimized for VSD operation
Advanced ABB open loop control software
Global ABB support

ABB Group
9/2/2011 | Slide 16
Draft of the efficiency IE4 with VSD supply

Conditions to describe efficiency levels for SPE range IE4


Supply Motor Efficiency level on Example Efficiency
motor level IE4 15 kW
DOL SPE Efficiency correspond 1500rpm
IEC IE4 level 94,0%
160-315 to new IE4 levels
VSD SPE (DOL)
Efficiency correspond IEC IE4 level 94,0%
160-315 to new IE4 levels with
sinusoidal voltage
supply

ABB Group
9/2/2011 | Slide 17
Losses and efficiency in electrical motors
Energy facts - 37kW 1500rpm

38,8 kW 39,9 kW
Loss
1,8 kW
Losses at 95,3 % (IE4)
Reduced losses = 1,1 kW

37kW Loss
2,9 kW
Losses at 92,7 % (IE2)

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

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

ABB Group
9/2/2011 | Slide 18
Performance data
Available SynRM offering
High output range Technical data

ABB Group
9/2/2011 | Slide 20
High output range
Technical data 1500rpm, M3BL160-315

ABB Group
9/2/2011 | Slide 21
High output range
Technical data 2100rpm, M3BL160-280

ABB Group
9/2/2011 | Slide 22
High output range
Technical data 3000rpm, M3BL160-250

ABB Group
9/2/2011 | Slide 23
Technical data
SynRM motor continuous loadability curve

1,1

0,9

0,8

T/Tn
T/Tn IC411
0,7
T/Tn IC416

0,6

0,5

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

n/nn

ABB Group
9/2/2011 | Slide 24
High output range
SynRM vs IM

Select SynRM packages based on actual power need


rather than based on IEC power rating !

ABB Group
9/2/2011 | Slide 25
SynRM motor performance compared to IM
SynRM & IM size 160MLB

ABB Group
9/2/2011 | Slide 26
Nominal speeds
SynRM 40kW 1500 - 2100 - 3000rpm
45

40

35

30
Power [kW]

25

20

15

10

0
0 500 1000 1500 2000 2500 3000 3500 4000

Speed [rpm]

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

ABB Group
9/2/2011 | Slide 27
Continuous and short time overloadability
SynRM and IM

250

200

150
Torque [Nm]

100

50

0
0 500 1000 1500 2000 2500 3000

Speed [rpm]

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

ABB Group
9/2/2011 | Slide 28