BSR Series

PRODUCTS &SOLUTIONS

BSR SeriesIE2-IE3-IE4

Synchronous Reluctance Motors

3

4 BSR series

5 BSR power drive system

6 Standard and directives

7 Efficiencyclassesandtestmethod

8 Symbolsandunitsofmeasure

9 Termsanddefinitions

10 Thesynchronousreluctancedrivesystem

12 SelectingtheBSRmotor

14 SelectingActiveCube410forBSRmotor

15 Ratingplate

16 BSRSeriesdesignation

18 Technicaldata

19 Torque-speedcharacteristic

20 Dimensionaltolerances

20 Bearings

21 Shaftloads

22 Flangeversions

22 Ventilation

23 Degreeofprotection

24 Insulationclass

24 Thermalprotection

25 Mountingpositions

26 Anti-condensationheaters

26 Secondshaftextension

27 Externalmechanicalprotection

27 Terminalbox

28 Dimensions

31 TheBSRgearmotorpackage

32 Powerdrivesystemenergyefficiency

34 BonfiglioliWorldwidePresence

Index

4

Thesynchronousreluctancemotorisanelectricmotorthatcombinesaconventionalthreephaseinductionmotorstatorwithaninnovativerotordesign.Therotorisdesignedwithamagneticanisotropyresultinginthereluctanceprinciplefortheelectromagneticenergyconversionwithoutusingpermanentmagnetsor rotorwindings. The rotordesignwith the laminationholes yields a lower inertia andbetter dynamics incomparisonwithaninductionmotorofthesamesize.

Thereductionofrotorlossesallowsanincreaseofmotorratingsincomparisonwithaninductionmotorintermsofbothefficiencyandpowerdensity.Takingtheadvantageofthisessentialfeature,BonfiglioliisabletooffertwodistinctiveversionsinBSRsynchronousreluctancemotorseries.TheHighEfficiency(E)versionischaracterizedbytheSuperPremiumIE4EfficiencyClasslevelatalltheratedoperatingpoints,includingthoseinthepartialloadrange.TheHighOutput(O)versionallowstoreducethemotorsizeincomparisonwithaninductionmotorofthesameoutputpower,maintaininganefficiencylevelequalorhigherthantheIE2EfficiencyClass.Whencomparedtohighefficiencyinductionmotors,thedynamicperformancesaresignificantlyhigher,thankstothelowerrotorinertia.

Key benefits• Efficient and Reliable: - Competitive advantagesintermsofTotalCostofOwnership - Highest energy efficiencysystemIES2andenvironmentallyfriendlysolution - Highlevelsofreliabilityduetoourproductionqualityprocessesandinternalknow-how• Dedicated to your application: - BSRmotorsaredesignedtoreplaceinductionmotorsinvariablespeedapplications,ensuring: > Energy efficiency increase up to class IE4ifcomparedwithinductionmotors >Areduction of the motor frameuptotwosizeswiththesamepowerofaninductionmotor - BSRmotors,incombinationwithActiveCube(ACU)410,provideaccurate speed, torque control - Suitable for any variable speed applications,whetherquadraticorconstanttorque Typicalapplicationsare:pumps,fans,compressors,conveyorsandwindingmachines• Wide power range: - 0.37…18.5kW• Accurate sensorless speed control: - BSRincombinationwithActiveCube410providesexcellentmotorcontrolwithoutencoderfeedbacks

Key features• High energy efficiencyofthemotoruptoclassIE4thatleadtoaremarkableenergysaving.• Extremelyhigh efficiencyfromthepartialloadrangeuptotheratedoperatingpoint• Higher torque densityincomparisonwithaninductionmotorofthesamesize• High dynamic responsethroughoptimizedcontrolandlowintrinsicmomentofinertia• High reliability and longer bearings lifethankstoloweroperatingtemperature• High overload capability:Upto300%ofratedtorque• Effective torque and speed control(alsoatlowspeed)withoutencoder• PerfectforretrofitthankstoIECmechanicaldimensions• OptimizedcompatibilitywithActive Cube 410driveseries.

Areas of application:

BSR series•SynchronousReluctancemotor Economicallyandenvironmentallysustainableinnovation

IllustrationofthesectionofaBonfigliolisynchronousreluctancemotorBSR(left)incomparisonwiththeoneofaninductionmotor(right).

FOOD & BEVERAGE

PACKAGINGMATERIALHANDLING

TEXTILE

5

TheBSRserieshasbeenspecificallycoordinatedandharmonizedwithActiveCube410frequencyinverterstodeveloptwosynchronous

reluctancepackages,onefocusedonenergyefficiencyandtheotheronefocusedonhighpowerdensity.

When comparing the synchronous reluctancemotor technology and the inductionmotor technology, themain advantagesof the two

packagesproposedbyBonfiglioliare:

• High Efficiency Package:higherefficiencyclass(uptoIE4)comparedtoaninductionmotorwiththesamepowerandframesize

ThankstoitsPremiumEfficiencyclassIE4,thispackageensuresaremarkabledecreaseintheenergyconsumption,whileensuringhigher

dynamicsincomparisonwithinductionmotorsduetolowerrotorinertia.

Thissolutioncontributestotheincreaseofthemachinereliability,thankstotheabsenceofrotor lossesandlessheatingdissipation,

leadingalsotoalongerlifetimeofbearings.

ThispackageisalsosuitableforinductionmotorsreplacementsincetheBSRmotorsaredesignedwiththesameframesizeasanIE2

inductionmotorofthesamepower.Hence,upgradingtothehighestefficiencylevelresultsinaneasyandsmoothprocess,withoutthe

needformechanicalmodifications.

TheHighEfficiencypackageisparticularlysuitedforthereplacementofinductionorPMmotorsinVariableSpeedDriveapplicationsand

forbasicapplicationssuchasPumps,Fans,Conveyors,Mixers,Dozers.

• High Output Package:smallerframeforsameoutputpowerandefficiencyclassofaninductionmotor

TheHighOutputmotor-drivepackageenablesthereductionofthemotorsizeuptotwoframesizes,oroptionally,theincreaseofthe

powerratingbetween20and100%forthesamemotorframe.

TheHighOutputmotorshaveIECdesignframeandmatcheswithstardardIECgearboxesonthemarket.

TheHighOutputpackageisparticularlysuitedforthereplacementofinductionorPMmotorsinVariableSpeedDriveapplicationsandfor

applicationswhichrequireaccuratesensorlessspeedandtorquecontrol.

Thetwodifferentpackagesensuretherightsolutionforhighefficiencyandcompactapplicationrequirements.

BSR power drive system

BSR 80C O 15-1.5kWIE2EfficiencyClass BE 90LA 4-1.5kWIE2EfficiencyClass

1 frame size less-35% Rotor inertia

Same efficiency class

BSR 90L E 15-1.5kWIE4EfficiencyClass BE 90LA 4-1.5kWIE2EfficiencyClass

Same frame size-24% Rotor inertia+5.4% Efficiency

6

BSRmotorsaremanufacturedinaccordancewithapplicableStandardsandDirectivelistedonthispage.

Standard and directives

BSRmotorsmeettherequirementsofDirectives2006/95/EC(LowVoltageDirectiveCEmarkisappliedtothisproduct).

Directives

STANDARD TITLE STANDARD TITLE

Generalrequirementsforrotatingelectricalmachines IEC60034-1

Terminalmarkinganddirectionofrotationofrotatingmachines IEC60034-8

Methodsofcoolingforelectricalmachines IEC60034-6

Dimensionsandoutputratingsforrotatingelectricalmachines IEC60072

Classificationofdegreeofprotectionprovidedbyenclosuresforrotatingmachines IEC60034-5

Noiselimits IEC60034-9

Classificationoftypeofconstructingandmountingarrangements IEC60034-7

Vibrationlevelofelectricmachines IEC60034-14

EfficiencyclassesofvariablespeedACmotors(IEcode) IECTS60034-30-2

Specifictestmethodsfordetermininglossesandefficiencyofconverter-fedACmotor IEC60034-2-3

Standard

7

Thestandard IEC60034-2-3definesthetestmethodsfordeterminingtotal losses includinghigh frequencymotorlossesandefficiencyoffrequencyinverterdrivenmotors(1).ForinverterdrivenmotorsliketheBSRmotorseries,theinput-outputmethodisapplied.Thestandarddefinessevenstandardizedoperationpointstocharacterizemotorlossesandefficiencyalongthecompletetorque-speedrange.Furthermore,theIEC60034-2-3providesaninterpolationprocedureforthelossdeterminationinanyoperatingpoint.

ThestandardIEC60034-30-2definestheinternationalenergy-efficiencyclassofvariablespeedACmotors.Theefficiencyclasses(IEcode)rangefromIE1(Standardefficiency)toIE5(UltraPremiumefficiency).

European Commission regulation 640/2009IEC standard 60034-30-2 establishes technical guidelines for efficiency classification but does not imposeany legalrequirements fortheadoptionofanyparticularefficiencyclass.Theseare laiddownbyEuropeanDirectivesandnationallaws.TheECRegulationapplyingDirective2009/125/ECwasadoptedonthe21stOctober2009.Thisestablishesthelegalrequirementsandeco-compatibledesigncriteriaforinductionmotors,andimposesminimumefficiencylimitsaccordingtothefollowingschedule:• 16/06/2011:InductionmotorsmusthaveaminimumefficiencylevelequivalenttoclassIE2• 01/01/2015:Inductionmotorswitharatedpoweroutputbetween7.5kWand375kWmusthaveaminimum efficiencylevelcorrespondingtoIE3,ortoIE2ifcontrolledbyafrequencyinverter• 01/01/2017:Inductionmotorswitharatedpoweroutputbetween0.75kWand375kWmusthaveaminimum efficiencylevelcorrespondingtoIE3,ortoIE2ifcontrolledbyafrequencyinverter

BSRmotorsincombinationwithActiveCube410frequencyinverterseriesmeetorexceedthelegalrequirementsforenergyefficiencyandareclassifieduptoclassIE4.

BSRmotorsarenotsubjecttoanyminimumefficiencyrequirementsforspecificcountries.

Efficiency classes and test method

STANDARDIZED OPERATING POINT

n T P

p.u. values refer to the nominal values

P1 0.9 1 0.9

P2 0.5 1 0.5

P3 0.25 1 0.25

P4 0.9 0.5 0.45

P5 0.5 0.5 0.25

P6 0.5 0.25 0.125

P7 0.25 0.25 0.0625

Torque[p

.u.]

Speed[p.u.]

00.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

0.5

0.25

0.75

1.0(3)

(7)

(2)

(5)

(6)

(4)

(1)

(1) IEC 60034-2-3 uses “converter” as a term for frequency inverters.

8

Symbols and units of measure

SYMBOL U.M. DESCRIPTION

η4/4 [-] EfficiencyatPn

fH [-] Altitudeadjustmentfactor

fn [Hz] Ratedfrequency

fT [-] Temperatureadjustmentfactor

In [A] Ratedcurrent

Iol [A] Overloadcurrent

Ip [A] Peakcurrent

Jm [kgm2x10-4] Motormomentofinertia

mIM B5 [kg] MasswithIMB5mounting

MEQU [Nm] Equivalenttorque

Mn [Nm] Ratedtorque

Mol [Nm] Overloadtorqueatnn

Mp [Nm] Peaktorque

nn [min-1] Rated speed

nmax [min-1] Maximumspeed

Pn [kW] Rated power

Unless otherwise specified, all dimensions are expressed in millimeters.

9

Duty type S1:Operationatconstantloadmaintainedforsufficienttimetoallowthemachinetoreachthermalequilibrium.

Duty type S3:sequenceofidenticaldutycycles,eachincludingatimeofoperationatconstantloadandatimede-energizedandatrest.Ifnotspecifiedthecycletimeisfixedequalto10minutes.

Electric time constant [τel]:isthetimetakenforthecurrenttoreach63.2%ofitssteadystatevaluewhenastepinputvoltageisappliedwhiletherotorisstationary.Itiscalculatedbydividingthewindingphase-to-phaseinductance(Lpp)bythewindingphase-to-phaseresistance(Rpp)at20°C.

Terms and definitions

τel=Lpp/Rpp

tf Worktimeunderconstantloadtr Rest time

Intermittence:

I = ∙ 100tf

tf + tr

P[kW]

t[°C]

tc

tf tr

t

Rated speed [nn]:isthespeedatwhichthemotorhasbeendesignedtooperatewithareasonablelevelofcontrol,intermsofoverloadtorque(Mol)andoverspeed.

Rated torque [Mn]:isthethermallypermissiblecontinuoustorqueforS1dutyattheratedmotorspeed(nn).

Thermal equilibrium:isthestatereachedwhenthetemperatureriseoftheseveralpartsofthemachinedonotvarybymorethanagradientof2Kperhour.

Thermal time constant [τtherm]:isthetimeforthetemperaturetoreach63.2%ofthisfinalvaluebetweenthemotorhousingandtheambientafterastep-wisecurrentchange.

Winding temperature rise [dT]:isthetemperaturerise,inspecifiedserviceconditions,ofthemotorwindingsabovethemaximumambientreferencetemperature.

Rated power [Pn]:isthemechanicalpoweravailableatshaftatratedspeednn.

Peak current [Ip]:isthecurrentusedtoproducethepeaktorque(Mp).Itisthecurrentlimitofthemachine,andifexceeded,evenforashortperiod,anirreversibledamagetothemachinecanoccur.

Peak torque [Mp]:istheabsolutemaximumtorquethatcanbeproducedbyamotorforashorttime.

Rated current [In]:istheRMScurrenttoproducetheratedtorque(Mn).

Overload current [Iol]:istheRMScurrenttoproducetheoverloadtorque(Mol)atratedspeed(nn).

Overload torque [Mol]:istheoverloadtorqueatratedspeed(nn).

Rated frequency [fn]:isthefrequencyofthefundamentalcomponentoftheoutputvoltagecorrespondingattheratedspeed(nn)accordingtothefollowingequationwherepisthepolepairs.

fn = p ∙ nn/60

Pn = 2π ∙ Mn ∙ nn /60

10

The synchronous reluctance drive systemSmartmotorcontrolforyourapplication

FLEXIBLE CONTROL STRATEGIES

ParameterIdentification

StartingOptions

Rotor Position Control

FluxControl

Optimized control for best PERFORMANCE and EFFICIENCY

Nom.Speed&Const.Torque

Range

HighSpeed&Const.

PowerRange

StartwithCurrentInjection

StartwithSensorless

FieldOrientedControl

SensorlessStartwithFeedback#

SensorBased#

Improved EfficiencywithMTPATable

OperationatVoltageLimit

Standard OptionforAcceleration

Ramps

AtfastAcceleration

Ramps

FundamentalModelwithImpedance

Map

Ifimplemented

Beneficialatverylow

Speed

TheBSRmotorsareoptimizedforoperatingwithActiveCube410inverterseries.ThankstothemotordataintegrationintheinvertersoftwareVPlus,thesetupisextremelyfastandeasy.TheresultingpowerdrivesystemmeetsalltherequirementsfortheIES2topefficiencyclassification.

Active Cube 410 Series

Power range:from0.25kWto400kW

Overload capacity• upto150%for60seconds• upto200%for1second

Motor Control(openlooporoptionalclosedloop):• AsynchronousACmotors• Synchronousreluctancemotors• Permanentmagnetsynchronous(brushless)motors

Communication modules• DifferentfieldbusoptionslikeCANopen,PROFIBUS,Modbus,EtherCAT,PROFINET,Varan• OptionalI/Oextensionsforaddtionaldigitalandanalogueinputs&outputs

# on request

11

The synchronous reluctance drive system guarantees excellent control performance thanks to optimized,model-basedsensorlesscontrol.

ThededicatedActiveCube410motorcontrolallowstooperatetheBSRmotorwiththesefeaturesandbenefits:•Exploitthemaximumpeaktorqueanddynamicthankstoaprecisefluxcontrol,•Maximizethemotorefficiencyevenatpartialloadthankstotheimplementedmotormodel,•Takeadvantageofthefieldweakeningcontrolathighspeed.

The synchronous reluctance drive systemIncreaseyourmachineproductivity

Flux Control Benefits: ExtractingMaximumTorque

Capability•EfficiencyOptimisation•FieldWeakening

ComprehensiveControlStructureforFlexibleAdaptiontoCountlessApplications

Field Oriented Sensorless Control:• Precisecontrolwith accuratemachinemodel• AchievingDynamicswith AdvancedMotorModel

Start-Up Manager:• NominalTorqueavailableat f=0Hz• VariousOptionsforany Application

SpeedReference

Ref.Flux

Est.Flux

Est.Speed

i

id

i*

u*

iq

u*

FieldWeakening

NominalSpeedRange

FieldController

SpeedController

CurrentController

Start-UpManager•CurrentInjection•FieldOrientedStart•Startwithmotorfeedback#

AdvancedMotorModel

Impedance Map

VoltageLimitOperation

OptimizedFluxTable

FluxEstimation

AngleEstimation

Sensorless Reluctance Motor Control with Active Cube 410

#oncustomerrequest

12

Selecting the BSR motor

(a) Equivalenttorque MEQU [Nm]

(b) Temperatureadjustingfactor fT -

(c) Altitudeadjustmentfactor fH -

(d) Equivalentcurrent IEQU [A]

13

Selecting the BSR motor

Select a bigger motor size

NO

NO

NO

START

END

Selecttherequiredmotorversion:E-HighefficiencyO-Highoutput

From load cycle determine:MaximumtorqueandrelativespeedMaximumspeedandrelativetorque

Select motor size, power rating and nominal speed



Calculateequivalenttorque

CalculatefT

CalculatefH

YES

YES

YES

Areallworkingpointsoftheloadcyclebelowthe

motorlimitcurve?

Mn*fT*fH > MEQU

Doesthemotorinertiamatchtheload

inertia?

(a)

(b)

(c)

14

Selecting Active Cube 410 for BSR motor

Select a bigger inverter size

NO

END

YES

IsACU410selectionfittingaccordingtoderating

figures?

Start Simplified Selection ACU410

Determinefromloadcycle:Mmax&tmaxcurrent:Maximumtorque&correspondingtime

MEQU:Equivalenttorque

SelectinverterbasedonImax,tmaxcurrent and IEQUConsidera10%currentreservewhenselectingthe

inverter

DeterminederatingfiguresaccordingtoACU410operatinginstructions*:

Temperature,Altitude,Voltage,SwitchingFrequency

Determinefrommotorselectionandloadcycle:DeterminekT= MN/IN

Imax:MaximumcurrentIMAX = MMAX/kT

IEQU:EquivalentcurrentIEQU = MEQU/kT

*: Derating has to be considered in these cases:More than 40°CMore than 1000 m altitudeMore than 3~ 400 V mains supplyPWM switching frequency 8 kHz or higher

15

InaccordancewithIEC60034-1,themotorratingplatesummarizesthemotorratingincludingthetotalweight.Exampleofratingplateandfield’sdescriptionarereportedhereafter.

Fields:1) Productdesignation2) Productcode3) Serialnumber4) Insulationclass5) Nominalpower6) Totalweight7) Degreeofprotection8) Motormounting9) Dutycycle10)Nominalfrequency11)Nominalvoltageandwindingconnection12)Nominalcurrent13)Nominalefficiencyatfullload14)Nominalspeed15)Maximumspeed16)Maximumambienttemperature17)Optiondata(e.g.fanunitdata)18)Efficiencyclass(IEcode)19)Driveendbearingtype20)Nondriveendbearingtype21)Serialnumberasbarcode

Rating plate

ExampleofBSRratingplate:

16

MOTOR

BSR Series designation

Degree of protection55 IP 55(2)

56 IP 56

Nominal line voltage40 400V(Yconnection)

Motor ratingE HighEfficiency(1)

O HighOutput

Nominal speed15 1500 min-1

30 3000 min-1

Motor typeBSR IEC3-PhaseSynchronousReluctanceMotor

Insulation classF ClassF(2)

H ClassH

BSR 40 FE80B 5515

Motor size71B … 132MB(IECMotor)

17

OPTIONS

Thermal protective devicesK1(5) SiliconsensortypeKTY84-130E3 ThermistorPTCP1 PlatiniumsensorPT1000

Forced ventilationU1(6) Powersupply1~230V(71-100),3~400VY(112-132)

Anti-condensate heatersH1 Powersupply1~230V

Double-extended shaftPS(6)

External mechanical protectionTC(6)

Rotor balancing grade BRV

...

Motor mountingB3 IMB3,IMB6,IMB7,IMB8,IMV5,IMV6B5 IMB5,IMV1,IMV3B14 IMB14,IMV18,IMV19B5R IMB5notstandardized(3)

B14R IMB14notstandardized(4)

B5

Notes:(1) Not available with nominal speed 3000min-1

(2) Default value(3) Flange with through holes with reduced coupling dimensions (4) Flange with tapped holes with reduced coupling dimensions. Not available for motor size 112 and 132 (5) Not compatible with insulation class H (6) Options U1, PS and TC are mutually exclusive

18

Operation with ACU410 frequency inverter series - rated voltage 400V - 1.5xMn overload at nominal speed (Mol) - 3xMn Peak overload (Mp)

4-pole 50 Hz 1500rpm Y Connection

Pn Size - Rating - Speed η4/4 IE Mn In Iol Ip nmax Jm mIM B5Suggested ACU410 inverter with

150% overload for max. 60 s

High Efficiency (E) - S1 duty cycle

kW % Code Nm A A A min-1 kgm2 x10-4 kg

0,37 BSR 71B E 15 81,5 IE4 2,4 1,1 1,5 2,9 2250 8 5,7 ACU410031F…0,55 BSR71C E 15 83,9 IE4 3,5 1,6 2,2 4,1 2250 10 7,1 ACU410031F…0,55 BSR 80B E 15 83,9 IE4 3,5 1,6 2,2 3,6 2250 17 9,5 ACU410031F…0,75 BSR80C E 15 87,0 IE4 4,8 2,2 2,9 5,1 2250 22 12,2 ACU410071F…1,1 BSR 90S E 15 88,3 IE4 7,0 3,0 3,9 7,0 2250 22 13,1 ACU410091F…1,5 BSR90L E 15 88,2 IE4 9,5 4,0 5,5 9,5 2250 26 14,5 ACU410122F…2,2 BSR100LA E 15 89,5 IE4 14,0 5,8 8,0 14,3 2250 45 22 ACU410132F…3 BSR100LB E 15 90,4 IE4 19,1 7,8 11,3 19,8 2250 50 24 ACU410152F…4 BSR 112M E 15 91,1 IE4 25 9,7 13,5 24,7 2250 82 31 ACU410193…5,5 BSR 132S E 15 92,1 IE4 35 13,5 18,8 36 2250 220 51 ACU410193…7,5 BSR132MA E 15 92,7 IE4 48 17,8 25,5 52 2250 255 57 ACU410213…9,2 BSR 132MB E 15 93,0 IE4 59 21,6 32 64 2250 280 67 ACU410223…

High Output (O) - S1 duty cylce

kW % Code Nm A A A min-1 kgm2 x10-4 kg

0,55 BSR 71B O 15 80,8 IE3 3,5 1,7 2,4 4,4 2250 8 5,7 ACU410051F…0,75 BSR71C O 15 82,5 IE3 4,8 2,1 3,4 6,2 2250 10 7,1 ACU410071F…0,75 BSR80A O 15 79,6 IE2 4,8 2,1 3,5 5,9 2250 13 8,0 ACU410071F…1,1 BSR 80B O 15 81,4 IE2 7,0 3,1 4,5 9,5 2250 17 9,5 ACU410091F…1,5 BSR80C O 15 82,8 IE2 9,5 3,9 6,9 10,9 2250 22 12,2 ACU410122F…2,2 BSR 90S O 15 85,9 IE2 14,0 5,6 8,2 16,8 2250 22 13,1 ACU410132F…3 BSR90L O 15 85,5 IE2 19,1 7,6 11,7 24,0 2250 26 14,5 ACU410152F…4 BSR100LB O 15 88,6 IE3 25 10,5 15,3 30 2250 50 24 ACU410193…5,5 BSR 112M O 15 89,6 IE3 35 13,5 19,5 42 2250 82 31 ACU410193…7,5 BSR 132S O 15 91,3 IE3 48 18,4 25,3 52 2250 220 51 ACU410223…9,2 BSR132MA O 15 91,6 IE3 59 22,0 33 66 2250 255 57 ACU410233…11 BSR 132MB O 15 91,5 IE3 70 24,7 32 77 2250 280 67 ACU410233…

Operation with ACU410 frequency inverter series - rated voltage 400V - 1.5xMn overload at nominal speed (Mol) - 3xMn Peak overload (Mp)4-pole 100 Hz 3000rpm Y Connection

High Output (O) - S1 duty cylcekW % Code Nm A A A min-1 kgm2

x10-4 kg

1,1 BSR 71B O 30 85,2 IE4 3,5 3,1 4,5 8,5 4500 8 5,7 ACU410091F…1,5 BSR71C O 30 87,1 IE4 4,8 4,2 6,2 11,7 4500 10 7,1 ACU410122F…1,5 BSR80A O 30 84,7 IE3 4,8 4,1 5,9 11,2 4500 13 8,0 ACU410122F…2,2 BSR 80B O 30 86,3 IE3 7,0 5,8 8,5 16,0 4500 17 9,5 ACU410132F…3 BSR80C O 30 88,3 IE3 9,5 7,8 11,6 19,7 4500 22 12,2 ACU410152F…4 BSR 90S O 30 90,2 IE3 12,7 9,9 15,2 27,3 4500 22 13,1 ACU410193…5,5 BSR90L O 30 90,9 IE4 17,5 13,5 20,6 43 4500 26 14,5 ACU410193…7,5 BSR100LB O 30 91,7 IE4 24 20,0 27,8 56 4500 50 24 ACU410223…11 BSR 112M O 30 91,9 IE3 35 24,5 36 77 4500 82 31 ACU410233…15 BSR 132S O 30 92,0 IE3 48 36 53 107 4500 220 51 ACU410273…18,5 BSR132MA O 30 92,4 IE3 59 43 62 126 4500 255 57 ACU410293…

Technical data

19

ThepermissibleoperatingrangeofaSynchronousReluctancemotor isdefinedbythermal,mechanicalandsensorlesscontrollimit.

ThebehavioroftheBSRsynchronousreluctancemotorisdescribedbyatorque-speedoperatingareaobtainedbythecombinationoftheBSRmotorseriesandtheActiveCube410frequencyinverterseries.Exceedingthenominalspeedthecontinuoustorquecurvedecreasesaccordingtotheconstantpowerlimit.Thecontinuousdutyzoneislimitedbythemaximumcontinuoustorquecurveandthevoltagelimitcurve.ContinuousdutyintheareaabovetheS1curveisnotpermitted.Theintermittentperiodicdutyzoneislimitedbythepeaktorquelineandthevoltagelimitcurve.

ThesignificantworkingpointsusedtodefinetheoperationzoneoftheBSRmotorsarehighlightedinthegraphaboveandthefollowingtable.Thevaluesrefertoratedtorque(Mn)andratedspeed(nn)as“perunit (p.u.)”expression,

(1) The value is valid only for BSR motor with nominal speed 1500 min-1

(2) The value is valid only for BSR motor with nominal speed 3000 min-1

Torque-speed characteristic

Voltagelimit

Torque[N

m]

Speed[min-1] nn nmax

Mp

Mol

Mn

Intermittent Duty

Continuous Duty

BSR ... E

BSR ... O

1

4

2

5

3

6

7

SYMBOL U.M. DESCRIPTION

1 2 3 4 5 6 7

Torque [p.u.] 0.4 1 0.4 1.5 3 3 1.5

Speed [p.u.] 0 0.4(1) 0.2(2) 1.5 0 0.3 0.8 1

Duty - Continuous Intermittent

20

Dimensionsandtolerancesofshaftend,keyandflangeareinaccordancewithIEC60072-1.ShaftendsfeatureanaxialthreadedholeinaccordancewithUNI3221,DIN332andakeyinsertedinthesuitablekeyway.Thefollowingtablereportsthetolerancesforthedifferentparts:

Dimensional tolerances

COUPLING DIMENSION DIMENSIONS RANGE TOLERANCE

Shaftend D - DAØ11-28 j6

Ø38-48 k6

Key F - FA - h9

Flange N Ø < 250 j6

BSRmotorsuseradialballbearings,lubricatedforlifewithgreaseandaxiallypre-loaded.Thetypeofbearingsinusearelistedinthefollowingtable.

(1) Only for the B5R motor mounting variant.

Bearings

SIZE PROTECTION DEGREE IP55 PROTECTION DEGREE IP56

DRIVE END NON DRIVE END DRIVE END NON DRIVE END

BSR 71 62022ZC3 62032ZC3(1) 62022ZC3 62022RSC3 62032RSC3(1) 62022RSC3

BSR 80 62042ZC3 62042ZC3 62042RSC3 62042RSC3

BSR 90 62052ZC3 62052ZC3 62052RSC3 62052RSC3

BSR 100 62062ZC3 62072ZC3(1) 62062ZC3 62062RSC3 62072RSC3(1) 62062RSC3

BSR 112 63062ZC3 63062ZC3 63062RSC3 63062RSC3

BSR 132 63082ZC3 63082ZC3 63082RSC3 63082RSC3

21

Themaxiumradialload(FR)andmaximumaxialload(FA)arecomputedusingISO281calculationL10hassumingabearinglifeof20.000h.Theloadandthespeedareassumedtobeconstantthroughoutthebearinglife.

Themaximumradialloadisreportedasafunctionofthedistance(X)betweenflangeplaneandthepointofforceapplicaton.ThemaximumradialloadsFRarevalidonlyforthehorizontalinstallationofthemotorwithoutadditionalaxialload.

Shaft loads

22

FlangeoutputmotorsareavailablewithreducedcouplingdimensionscorrespondingtoproductvariantsB5R(withthroughholes)andB14R(withtappedholes).Dimensionsareindicatedinthetablebelow:

Flange versions

ThestandardBSRmotorisequippedwithaself-coolingfan(IC411inaccordancewithCEIEN60034-6).Thefanandtheresultingcoolingisoptimizedforratedspeed.Installationmusttakeintoaccountaminimumdistanceofthefancoverfromthenearestwalltoensureunobstructedaircirculation.FormachinesoperatingfrequentlyorforlongperiodsoftimeatsmallspeedstheBSRmotorcanbeequippedwiththeoptionalfanunitU1(referredtoasIC416instandardCEIEN60034-6).TheterminalsoftheU1fanunitarehousedinaseparateterminalbox.

ThefollowingtablesummarizestheelectricaldataofthefanunitU1andtheincreaseofmotorlength.

(1) Dimension variation compared to length LB of the corresponding standard motor.

Ventilation

MOTOR SIZE ELECTRICAL DATA OF FAN UNIT U1 ΔLB(1)

VAC ±10% Hz P [W] I [A] [mm]

BSR 71

1~230

50/60

22 0.12 93

BSR 80 22 0.12 127

BSR 90 40 0.30 131

BSR 100 50 0.25 119

BSR 1123~230Δ/400Y

50 0.26/0.15 130

BSR 132 110 0.38/0.22 161

SIZE D E M N P

BSR 71B5R 11 23 115 95 140

B14R 11 23 75 60 90

BSR 80B5R 14 30 130 110 160

B14R 14 30 85 70 105

BSR 90 B5R 19 40 165 130 200

B14R 19 40 100 80 120

BSR 100B5R 24 50 165 130 200

B14R 24 50 115 95 140

BSR 112 B5R 24 50 165 130 200

BSR 132 B5R 28 60 215 180 250

23

IP55isusedasdefaultprotectionclassfortheBSRmotorconfiguration.OptionallytheprotectionclassIP56isavailableasvariant,pleasechecktheproductdesignation.InaccordancewithIEC60034-5:

Degree of protection

Not protected

ProtectedagainstextraneoussolidbodieshavingØ≥50mm

ProtectedagainstextraneoussolidbodieshavingØ≥12.5mm



Nodustingress

Protectedagainstdust

Not protected

Protectedagainstverticalwater drips

Protectedagainstverticalwaterdripsinclinedupto15°

Protectedagainstrain

Protectedagainstwatersplashes

Protectedagainstpowerfuljetsofwater

Protectedagainsttheeffectsoftemporaryimmersion

Protectedagainsttheeffectsofcontinuousimmersion

Protectedagainstjetsofwater

24

BSRmotorsaredesignedaccordingtoclassFinsulatingmaterialsasstandardvariant.OptionallytheinsulationclassHisavailableforBSRmotors.Forapplicationinvolvingthepresenceofaggressivechemicalsorhighhumidity,pleasecontactBonfiglioli.

DuringthecommissioningoftheActiveCube410frequencyinverter,theconnectedBSRmotorissetup.DuringthissetupasoftwareI²tmonitoringisactivatedofferinganinexpensivesolutionforthermalmonitoringwiththepossibilitytosetupafaultswitchoffinsidethefrequencyinverter.OptionallytheBSRmotorcanbeequippedwithahardwarethermalswitchthatcanbeevaluatedwiththeActiveCube410.Ahardwaremonitoringisespeciallyrecommendedformotorswithforcedventilation(U1option).Theavailablethermalswitchesare:

Insulation class

Thermal protection

F H

Hottestpointmarginwithtemperaturedeterminationbyresistancemethod

Increaseallowedbythetemperature

Max.ambienttemperature

OPTION THERMAL SWITCH DESCRIPTION

K1 TypeKTY84-130

AKTYsiliconsemi-conductorresistancesensorisplacedincontactwiththemotorwinding.Theworkingtemperaturerangeisfrom0°Cto170°C.ThissensorcannotbeusedincombinationwithinsulationclassH.

E3 PTC

3PTCthermistorsareplacedincontactwiththemotorwinding.Thethermistorswitchtemperatureisinaccordancewiththeinsulationclassofthemotor.ForthePTCthermistorresistancecurvepleaserefertotheStandardDIN44081-82.

P1 PT1000

Aplatinumresistancetemperaturesensorisplacedincontactwiththemotorwinding.ThePT1000characteristicisinaccordancewithIEC60751:2008,toleranceclassB.Theworkingtemperatureisfrom-40°Cto250°C.

25

EC-normalisedBSRmotorsareavailableinthedesignversionsasindicatedinthefollowingtableaccordingtoStandardsEN60034-7.

BSRisavailablewiththefollowingmountingversions:IM B3(basic)IMB6,IMB7,IMB8,IMV5,IMV6(derived)IM B5(basic)IMV1,IMV3(derived)IM B14(basic)IMV18,IMV19(derived)

IMB3designmotorscanbeinstalledinpositionsIMB6,IMB7,IMB8,IMV5andIMV63;IMB5designmotorscanbeinstalledinpositionsIMV1andIMV3;IMB14designmotorscanbeinstalledinpositionsIMV18andIMV19. Insuchcases,thebasicdesignIMB5orIMB14isindicatedonthemotornameplate.

Mounting positions

26

Whereanapplication involveshighhumidityorextremetemperaturefluctuations,motorscanbeequippenoptionallywithananti-condensationheater(optionH1).Asingle-phasepowersupplyisavailableintheauxiliaryterminalboardinsidethemainterminalbox.Thefollowingtablesummarizestheelectricalpropertiesoftheanti-condensationheater.

Anti-condensation heaters

VOLTAGE POWER

[V] [W]

BSR71-BSR801~230±10%

10

BSR90…BSR132 25

Second shaft extension

AsecondshaftextensionisavailableselectingtheoptionPS.ThisoptioncannotbeusedincombinationwithoptionsU1orTC.Theshaftdimensionscorrespondtothefirstshaftandaresummarizedinthedimensionstableinthiscatalogue.

27

Terminalboardfeatures6studsforeyeletterminalconnections.Agroundterminalisalsosuppliedforheartingoftheequipment.Terminalnumberanddimensionareshowninthefollowingtable.InmotordesignIMB3,theterminalboxisonthetop(sideoppositetofeet).

ThecableentriesoftheterminalboxesusemetricthreadsinaccordancewithstandardEN50262asindicatedinthefollowingtable.

Terminal box

BSR SIZE NUMBERS OFTERMINALS

TERMINALTHREADS

WIRE CROSSSECTION AREA

[mm2]

BSR71…BSR906

M4 2.5

BSR100…BSR132 M5 6

BSR SIZE CABLE GLAND AND DIMENSIONS MAXIMUM CABLEDIAMETER ALLOWED

[mm]

BSR 71 2xM25x1.51Holeoneachside

17

BSR80...BSR90 2xM25x1.5 17

BSR100...BSR112 2xM32x1.52xM25x1.5 2Holesoneachside

2117

BSR 132 4xM32x1.5 21

Inapplicationswithhigh riskofobstructionsof the fan (i.e. flying lints in textile industryenvironments) theoptionTC(textilecanopy)canbeaddedasoption.Thefollowingtablesummarizesthedimensionspermotorsize.

AQ ΔV

BSR 71 134 27

BSR 80 152 25

BSR 90 168 30

BSR 100 190 28

BSR 112 211 32

BSR 132 254 32

External mechanical protection

28

Dimensions

B3

SHAFT

D DA E EA DB GA GC F FA

BSR 71 14 30 M5 16 5

BSR 80 19 40 M6 21,5 6

BSR 90 24 50 M8 27

5BSR 10028 60 M10 31

BSR 112

BSR 132 38 80 M12 41 10

HOUSING B3

B A HA BB AB K C H

BSR 71 90 112 8 112 135 45 71

BSR 80100

125 8 124 153

10

50 80

BSR 90 S140 8 155 174 56 90

BSR 90 L 125

BSR 100140

16010 175

192

12

63 100

BSR 112 190 224 70 112

BSR 132 178 216 12 218 254 89 132

MOTOR

AC L LB LC AD AF LL V

BSR 71 138 249 219 281 10874 80

37

BSR 80 156 274 234 315 119 38

BSR 90 176 326 276 378 133

98 98

44

BSR 100 195 367 307 429 142 50

BSR 112 219 385 325 448 157 52

BSR 132 258 493 413 576 193 118 118 58

EA: Second shaft available as option

29

Dimensions

B5

SHAFT


BSR 71 14 30 M5 16 5

BSR 80 19 40 M6 21,5 6

BSR 90 24 50 M8 27

5BSR 10028 60 M10 31

BSR 112

BSR 132 38 80 M12 41 10

HOUSING B5

M N P S T LA

BSR 71 130 110 160 9.5

3.5

10

BSR 80165 130 200 11.5 11.5

BSR 90

BSR 100215 180 250

14 4

14

BSR 112 15

BSR 132 265 230 300 20

MOTOR


BSR 71 138 249 219 281 10874 80

37

BSR 80 156 274 234 315 119 38

BSR 90 176 326 276 378 133

98 98

44

BSR 100 195 367 307 429 142 50

BSR 112 219 385 325 448 157 52

BSR 132 258 493 413 576 193 118 118 58


30

Dimensions

B14

SHAFT


BSR 71 14 30 M5 16 5

BSR 80 19 40 M6 21,5 6

BSR 90 24 50 M8 27

5BSR 10028 60 M10 31

BSR 112

BSR 132 38 80 M12 41 10

HOUSING B14

M N P S T

BSR 71 85 70 105M6

2.5

BSR 80 100 80 1203

BSR 90 115 95 140

M8BSR 100130 110 160 3,5

BSR 112

BSR 132 165 130 200 M10 4

MOTOR


BSR 71 138 249 219 281 10874 80

37

BSR 80 156 274 234 315 119 38

BSR 90 176 326 276 378 133

98 98

44

BSR 100 195 367 307 429 142 50

BSR 112 219 385 325 448 157 52

BSR 132 258 493 413 576 193 118 118 58


31

The BSR gearmotor package

Control, flexibility, efficiency and compactness are fundamental characteristics in a wide range of industrialprocessesandapplications.Tomatch these needs Bonfiglioli has developed a new solution, represented by the Bonfiglioli synchronousreluctancemotor(BSR),combinedwiththehelicalorwormtechnologyofBonfiglioliA,C,F,SandVF-Wgearunits.ThesynergybetweenBSRmotorsandA,C,F,SandVF-WgearboxesallowstoexploittherobustnessandwidetorquerangeofBonfiglioli industrialgearunits,aswellas theflexibilityandefficiencyofBonfiglioli reluctancemotors.

Maximum FlexibilityTwodifferentsolutionsavailable:•HighEfficiencyPackage:BSRinIE4efficiencyclasscombinedwithA,C,F,Sgearboxes•HighOutputPackage:BSRinIE2,IE3,IE4efficiencyclasscombinedwithA,C,F,SandVF-Wgearboxes

ModularityThemodularcouplingbetweenBSRandBonfiglioligearboxesguaranteesextendedcustomizationcapability.Indeed,thefullrangeofversionsandoptionsoftheA,C,F,SandVF-Wgearboxes,canbeusedtocustomizethesolutionandperfectlymatchcustomers’needs.

One stop shopAll the componentsof thedrivepackagearemanufacturedbyBonfiglioli. This ensures thehighest levelofperformancesandcompatibility.Atthesametimeourcustomerscanrelyonauniquesupplierforallgearboxes,motorsandinverters.

Areas of Application

PACKAGING RORATYTABLE

ROTARYMACHINES

PICK & PLACE SOLUTIONS

MATERIALHANDLING

32

TheinternationalstandardIEC61800-9dealswiththeenergyefficiencyofcompletedrivemodules(CDM)andpowerdrivesystems(PDS).ThestandardIEC61800-9isharmonizedinEuropeasEN61800-9andreplacestheearlierstandardEN50598(-1and-2).Asrepresentedinthefollowingdiagram,thepowerdrivesystemconsistsofthecompletedrivemoduleandtheelectricalmotor,includingthemotorcable.ThestandarddefinestheIEclassesforCDMandtheIESclassesforPDS.

TheIECstandard61800-9-2specifiestheprocedurefordeterminingthe lossesofthePDSin8application-relevantoperatingpointsformotordriveapplicationsinthepowerrangefrom0.12kWto1,000kW.Lossesof the referencepowerdrivesystem (RPDS)aredefined for the8specificoperatingpointsand theinternationalefficiencyofsystemsclasses(IES)forthePDS.ThePDSenergyefficiencyisclassifiedintherangeofIES0-IES2asdescribedinthefollowingillustration.

Illustrationoftheoperatingpoints(shaftspeed,torque)forthedeterminationoftherelativelossesofthePDSaccordingtoIEC61800-9-2.

IllustrationoftheIESclassesofaPDSaccordingtoIEC61800-9-2.

Power drive system energy efficiency

PDS

Electricpowerfrommains

Motorelectricpower

Mechanicalpoweronshaft

CDMlosses Motorlosses

MainsSupply CDM Motor Load

PDSrelativetorque(%

)

PDSrelativespeed(%)50 100

50

25

100pL,PDS(0;100)

pL,PDS(0;50)

pL,PDS(0;25) pL,PDS(50;25)

pL,PDS(50;100)

pL,PDS(50;50)

pL,PDS(100;100)

pL,PDS(100;50)

[3] [2] [1]

[6] [5] [4]

[8] [7]

0%IEC

IES2

IES1

IES0

120%

80%

100%

50%

pL,PDS(100;100)

pL,RPDS(100;100)

33

Thefollowingtablessummarizetherelative losses intheoperatingpointsdefinedinthestandardIEC61800-9-2.ThetablesshowsthelossesforthesuggestedcombinationsofBSRandActiveCube410.

Power drive system energy efficiency

Pn Size - Rating - Speed IES RPDS IES1 Operating points

kW Class Point 1 1 2 3 4 5 6 7 8

0,37 BSR 71B E 15 IES2 79,7% 32,1% 29,2% 26,1% 24,1% 19,4% 15,2% 14,9% 13,1%

0,55 BSR71C E 15 IES2 61,4% 29,1% 27,7% 24,1% 19,7% 14,7% 15,1% 11,2% 10,1%

0,55 BSR 80B E 15 IES2 61,4% 31,1% 28,5% 25,9% 23,0% 18,9% 16,7% 14,7% 12,5%

0,75 BSR80C E 15 IES2 51,7% 24,6% 22,0% 19,9% 16,0% 14,1% 13,1% 10,3% 9,5%

1,1 BSR 90S E 15 IES2 44,0% 21,0% 18,0% 15,2% 14,3% 11,6% 10,3% 8,0% 7,3%

1,5 BSR90L E 15 IES2 39,1% 20,6% 17,4% 15,2% 13,5% 10,2% 9,0% 7,2% 6,2%

2,2 BSR100LA E 15 IES2 34,6% 18,9% 15,9% 15,0% 11,8% 9,1% 8,5% 6,1% 5,5%

3 BSR100LB E 15 IES2 31,6% 16,9% 16,1% 15,1% 10,1% 8,3% 7,6% 5,0% 4,4%

4 BSR 112M E 15 IES2 29,1% 13,9% 11,8% 10,4% 7,5% 6,1% 5,4% 4,7% 3,2%

5,5 BSR 132S E 15 IES2 26,6% 12,9% 11,4% 9,8% 7,4% 5,1% 4,9% 3,5% 2,8%

7,5 BSR132MA E 15 IES2 24,1% 11,4% 10,1% 8,5% 6,8% 4,7% 3,9% 2,6% 2,8%

9,2 BSR 132MB E 15 IES2 - 9,7% 7,8% 7,1% 4,8% 4,1% 3,2% 2,0% 1,9%

0,55 BSR 71B O 15 IES2 61,4% 36,6% 45,0% 48,9% 20,8% 18,4% 16,6% 12,2% 11,4%

0,75 BSR71C O 15 IES2 51,7% 32,4% 30,2% 22,2% 15,4% 12,7% 10,2% 9,6% 9,1%

0,75 BSR80A O 15 IES2 51,7% 36,6% 35,1% 29,1% 20,8% 18,4% 16,6% 12,2% 11,4%

1,1 BSR 80B O 15 IES2 44,0% 32,5% 31,2% 24,8% 16,3% 13,1% 11,1% 9,4% 8,8%

1,5 BSR80C O 15 IES2 39,1% 28,0% 30,0% 25,1% 13,1% 12,0% 10,9% 12,0% 7,0%

2,2 BSR 90S O 15 IES2 34,6% 21,8% 22,0% 22,6% 11,1% 9,3% 9,0% 5,6% 5,0%

3 BSR90L O 15 IES2 31,6% 21,4% 21,5% 20,5% 10,0% 8,5% 8,1% 4,9% 4,6%

4 BSR100LB O 15 IES2 29,1% 18,4% 19,3% 19,6% 9,1% 7,8% 7,1% 4,6% 4,1%

5,5 BSR 112M O 15 IES2 26,6% 17,1% 18,3% 17,9% 8,1% 7,0% 6,2% 4,0% 3,6%

7,5 BSR 132S O 15 IES2 24,1% 15,3% 17,0% 16,4% 7,1% 6,3% 5,3% 3,4% 3,2%

9,2 BSR132MA O 15 IES2 - 13,6% 15,7% 14,9% 6,1% 5,5% 4,4% 2,9% 2,7%

11 BSR 132MB O 15 IES2 21,7% 11,9% 14,3% 13,4% 5,1% 4,7% 3,4% 2,4% 2,3%

1,1 BSR 71B O 30 IES2 44,0% 26,1% 23,1% 19,4% 17,5% 11,1% 10,1% 8,1% 6,9%

1,5 BSR71C O 30 IES2 39,1% 24,9% 21,4% 20,1% 17,4% 10,1% 9,8% 8,4% 6,1%

1,5 BSR80A O 30 IES2 39,1% 25,3% 22,1% 19,3% 16,2% 11,5% 9,3% 7,5% 5,5%

2,2 BSR 80B O 30 IES2 34,6% 21,8% 18,7% 15,9% 13,5% 9,6% 7,9% 5,7% 4,4%

3 BSR80C O 30 IES2 31,6% 17,6% 16,8% 12,7% 11,0% 7,5% 12,2% 4,8% 11,7%

4 BSR 90S O 30 IES2 29,1% 15,4% 13,2% 9,7% 9,7% 6,5% 5,1% 4,1% 3,1%

5,5 BSR90L O 30 IES2 26,6% 14,6% 13,1% 12,7% 8,3% 5,6% 5,0% 3,3% 2,7%

7,5 BSR100LB O 30 IES2 24,1% 14,8% 11,7% 9,8% 8,9% 5,7% 7,7% 3,4% 6,6%

11 BSR 112M O 30 IES2 21,7% 10,2% 8,4% 5,7% 6,3% 4,1% 3,1% 3,1% 3,0%

15 BSR 132S O 30 IES2 19,9% 11,0% 7,5% 4,9% 6,0% 4,0% 3,0% 2,8% 2,9%

18,5 BSR132MA O 30 IES2 18,9% 9,0% 6,5% 4,7% 5,9% 3,9% 2,7% 2,6% 2,4%

34

Global Presence

We Are a Global CompanyThankstoaninternationalnetworkofsalesbranchesandcloselyinterconnectingproductionplants,wecanguaranteethesamehighstandardsofBonfiglioliqualityanywhereatanygiventime.Awarethatourdirectpresenceinlocalmarketsisthekeytolong-lastingsuccess,ourfamilyincludes20salesbranches,13productionplantsandmorethan500distributorsaroundtheworld.

Our organization is always close by, off ering complete and effi cient solutions and supporting our customers with dedicated services, such as co-engineering or after-sales assistance.

Bonfiglioliisamarketforcewithapresencespanning22countrieson5continents.Ourorganizationmakesthemostofgeographicproximitytooffercompletesolutionscombiningefficiencyandcompetence.

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