EMZ high-voltage motors & drive systems - EMK- · PDF fileEMZ high-voltage motors & drive systems ... AKD/L/W squirrel-cage rotors ... 450, 500 and 560 mm and can be manufac

EMZ high-voltage motors & drive systems

→ Product series of EMZ high-voltage motors → Resistant starters and electrical soft starters → Medium-voltage frequency converters

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Preface

Dipl.-Ing. Benedikt Mathiaszyk

Managing Director Large Drive & Projects

Dear Ladies and Gentlemen,

We are pleased to present our product series of high-

voltage motors and large drives to you with this catalogue.

EMZ stand for products and services of excellent quality,

quick delivery and competitive prices. With the use of mod-

ern manufacturing processes and high quality materials,

we guarantee maximum reliability and operational safety.

Thanks to our years of experience, we are familiar with

the comprehensive requirements of internationally-

operative OEMs and know the practical needs of the

operators in the plants.

Our qualified sales team take your individual require-

ments into account and provide personal, expert advice

to help you choose the right high-voltage drives and

complete drive-systems.

Ask us; we will be delighted to assist you with your

enquiries and look forward to working with you.

EMZ‘s premises in Recklinghausen

cover 20,000 m2, whereby 5,000 m2

alone are for warehousing, a further

1,800 m2 for workshops and 800 m2

used for office space.

3EMZ High-voltage motors

Norms and Standards

EMZ high-voltage motors and drive-systems are

manufactured according to current IEC and EN 60034

standards and comply with the following regulations:

Design & performance DIN/EN 60034-1

Protection type DIN/EN 60034-5

Cooling DIN/EN 60034-6

Construction type DIN/EN 60034-7

Noise emission DIN/EN 60034-9

Vibration levels DIN/EN 60034-14

Electrical insulation DIN/EN 60085

Soft starters DIN/EN 60947-4-2

Frequency converters DIN/EN 61800

On request, the EMZ motors can be manufactured

in accordance with NEMA MG2 standards and IEEE

testing regulations.

Applications & Guidelines

Applications

We are represented worldwide in all branches, e.g.

cement, chemicals, paper, steel and plant engineering.

With our qualified personnel we guarantee optimal and

individual support during every phase of the project.

Reliability and service are the highest priority at EMZ.

See for yourself!

Made by EMZ

To offer you a top-quality drive-system concept, the

right choice of manufacturing facilities is crucial. The

high quality standards of our products are guaranteed

by the certification of our production sites in accord-

ance with EN ISO 9001 standards.

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Our Product Range

4

01 02 03Compact Series

AKR squirrel-cage motors

ASR slipring motors

→ Cooling type IC411

→ Rib-cooled squirrel-cage

motors and slipring motors

Modular Series

AKD/L/W squirrel-cage rotors

ASD/L/W slipring motors

→ Cooling types IC01/611/W81

→ Modular squirrel-cage motors

and slipring motors

Special Designs

Taylor-made individual construction

→ 100 % interchangeable replicas

→ Special designs for individual

drive application

→ Development of appropriate

drive concepts

→ Cooling types IC

01/31/411/511/611/W81

→ Customised designs


04 05 06Synchronous machines

SD/L/W synchronous machines

→ Cooling types IC 01/611/W81

→ Modular synchronous motors

and generators

Soft Starters & Resistance Starters

Soft starters for squirrel-cage

motors

Liquid and oil cooled resistance

starters for slipring motors

Frequency Converters

Low-voltage 690 V up to 2,500 kW

Medium voltage

2,200 V to 11,000 V for engine

performance of max. 30 MW

5EMZ High-voltage motorsHigh-voltage motors

6

Our Resources for High-Voltage Motors

Design and Calculation

→ 3D construction tools

→ Optimised stator housing

design

→ Torsion analysis of shafts

→ Magnetic calculation of

active parts

→ Low-noise fan design

→ Optimised efficiency

Construction

Compact series AKR/ASR

→ Compact cast-iron frame

→ dual-circuit cooling system

with internal and external fan

→ Low-vibration bearing end shield

construction

→ Optimised performance and

maximum power in a

compact design

Modular series AKL/ASL

→ Modular basic concept

→ Different types of protection

and cooling feasible

→ Torsion-resistant welded

steel housing

→ Direct derivation of the

torque to the base construction

→ Realisation of the mechanical

dimensions according to the

customer’s specifications

High-Voltage Windings

→ Corded two-layer winding design

→ Voltages 3,000 V to max. 15,000 V

→ High-voltage windings in thermal

classes F and H

→ Thermal load in thermal class

B (80K)

→ Advanced VPI technology

→ Robust design of the coil-winding

heads with great mechanical stability

01 02 03


Rotor windings

Squirrel-cage rotors

→ Squirrel-cage motors with

robust copper windings for

tough start-up conditions

→ Reduced heat-transfer

resistances

→ Grooved and hard-soldered

bar/ring connections

→ Standard applications with

aluminium winding

Slipring rotors

→ VPI insulation

→ Insulation system in

thermal classes F and H

→ Great mechanical stability

Bearings

→ High-quality SKF and FAG

ball/roller bearings

→ Fixed bearings of standard

design on the DE-side

→ Reinforced bearings (DE)

for belt drive application

→ Special construction for

higher axial loads

→ High-quality Renk sleeve

bearings with oil-ring lubrication

→ Special designs for

sleeve bearings with

hydrostatic device

Testing

→ All measurements according to

IEC/EN 60034-1 regulations

→ All motors undergo complete

routine testing

→ Type testing including

thermal measuring on request

→ Special testing:

→ Tan Delta measuring

→ Impulse-voltage testing

according to IEC/EN 60034-15

→ Polarisation index

→ Vibration analyses

→ Single-coil testing

04 05 06

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The innovative dual-circuit cooling system, with its

unidirectional internal fan, ensures a consistent tem-

perature distribution inside the motor. This increases

the service life and the reliability of the machine.

Our motors are available in the IEC frame sizes 315,

355, 400, 450, 500 and 560 mm and can be manufac-

tured with a maximum output of 1,800 kW.

AKR motors are suitable for heavy and extreme condi-

tions. They are available in standard design for opera-

tion with fixed speed but also for speed-regulated use

with frequency converters.

AKR seriesThe rib-cooled squirrel-cage motors of our AKR series

are manufactured with a cast-iron housing as standard.

A compact design and great reliability characterise our

motors.

Thanks to the optimised dimensioning of the stator,

rotors and fan, losses are reduced and optimum

efficiency values achieved.

AKR engines are surface cooled according to IC411

(IEC 60034-6) and transfer the heat losses via the

ribbed motor housing and the bearing end shield to the

external cooling air.

Surface-cooled three-phase squirrel-cage motors


Design

→ Manufactured according to the current

DIN, IEC and EN standards

→ Compact cast-iron housing

→ High output related to frame size

→ Two-circuit cooling system for

internal and external cooling

→ Reliable bearing design with SKF/FAG

rolling bearings

→ Fixed bearing on the DE-side

→ VPI insulation system in thermal class F

→ Use of copper rotors for difficult

start-up conditions

→ Designed for use with fixed speed and

for VFD application

Power range

→ Performance 150 to 1,800 kW

→ Voltage 2,000 to 11,000 V

→ Frequency 50 and 60 Hz

→ Number of poles 2 to 12-pole

→ Protection type IP 55

→ Cooling type IC 411

→ Mounting IM B3 and IM V1

Applications

→ Pumps

→ Compressors

→ Ventilators

→ Chippers/Refiner

→ Conveyor drives

→ Mills

550 kW squirrel-cage motor AKR 355-04 as a drive for a vacuum

blower for a paper factory.

Final assembly 800 kW squirrel-cage motor AKR 450-04.

01 | Compact Series

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AK seriesBased on the basic module of a welded stator housing,

the squirrel-cage motors of the AK series can be adapted

perfectly to suit the individual requirements of each

application.

The high-quality design and manufacture guarantee

the reliability of EMZ motors.

The following types are available

(type designation according to IEC 60034-5/6):

AKD series

Protection type IP23/W24/R54

cooling type IC01/31

AKL series

Protection type IP55 | cooling type IC611/616

AKW series

Protection type IP55 | cooling type IC81W

Modular three-phase squirrel-cage motors

Thanks to the use of roller bearings by the manufac-

turers SKF and FAG, we guarantee extended operation

interval and low maintenance costs.

All motors can be supplied on request with oil ring

lubricated sleeve bearings manufactured by Renk.

Depending on the bearing loads, the sleeve bearings are

self-cooled or externally-cooled with an oil lubrication

unit.

The rotor windings of the basic design are made of rec-

tangle copper bars which are hard-soldered with the

grooved short circuit rings. For special applications with

difficult start-up and operating conditions, we use dou-

ble-cage rotors. For high speed applications, the end

rings are secured with additional antimagnetic stain-

less steel retainer rings.


Power range


→ Voltage 2,000 to 13,800 V


→ Number of poles 2 to 24 pole

→ Protection type IP 23/W24/R54/55

→ Cooling type IC 01/31/611/81W

→ Mounting IM B3 and IM V1/V10

Applications

→ Pumps

→ Compressors

→ Ventilators

→ Chippers/Refiner

→ Shredders

→ Conveyor drives

→ Mills/crushers

1,200 kW fan drives for AKL 560-06 for a cement plant. 2,500 kW refiner drive AKL 710-06 for the paper industry.

02 | Modular Series

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Modular housing design

The base of AS slipring rotors is a compact and

modular housing construction. The welded stator hous-

ing is ribbed on the inside and designed to be very sta-

ble and torsion-resistant. The torque loads and peak

loads that occur during operation are diverted directly

to the base construction and the foundations.

With modular cooling elements, all the necessary

protection and cooling types can be realised.

AS seriesSlipring motors are used when a high starting torque

and/or a low starting current is/are required. These

motors offer maximum availability and are used espe-

cially in applications with high external moment of iner-

tia, such as mills and big fans or where the main power

supply is weak.

Identical to the modular cage-rotor series, the slipring

motors of the AS series are development onto the basic

module of the welded stator-housing construction.

Modular three-phase slipring motors


Rotor design

Depending on the size of the motors, a cylindrical or

a welded spider shaft is used for the rotor. By using

massive shafts, all slipring rotors can be constructed

with a second shaft end designed for twice the nominal

torque. The rotor winding is executed in thermal class F

and manufactured as a corded two-layer winding. The

individual rotor bars are hard-soldered after insertion

and secured with a sturdy bandage against the occur-

ring centrifugal forces.

Bearings

By using high-quality rolling bearings manufactured

by SKF and FAG and sleeve bearings manufactured

by Renk, we can guarantee a long service life and low

maintenance costs.

The following designs are available

(descriptions according to IEC 60034-5/6):

ASD series

Protection type IP23/W24/R54 | cooling type IC01/31

ASL series

Protection type IP55 | cooling type IC611/616

ASW series

Protection type IP55 | cooling type IC81W

Quality

The entire manufacturing process, from design to exe-

cution, manufacture to final testing, is integrated into the

quality assurance system according to EN ISO 9001.

Spider shaft of a 4,000 kW slipring rotor during assembly. 4,000 kW ball-mill drive ASL 710-06 in a cement mill.

02 | Modular Series

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Service

The use of high-quality carbon brushes and brush hold-

ers, as well as the load-optimised design of the carbon

brushes, are essential criteria for low wear-and-tear

parameters.

With our qualified staff, we offer an all-round service

for the operation and continuous monitoring of the slip-

ring system during operation within the facility, thus

ensuring that our customers benefit from a high level

of operational safety and reliability.

Modular three-phase slipring rotor

Slip rings & carbon brushes The standard version slipring motors are available with

permanently-mounted carbon brushes or, on request,

with a short-circuit and brush-lifting device. In both cas-

es, the slipring body is mounted on the NDE-side. For

the execution with the permanently-mounted carbon

brushes, the slipring compartment is designed with a

separate cooling circuit that is seperated from the sta-

tor winding and equipped with filter pads for the carbon-

brush dust.

The standard version corrosion-resistant sliprings are

manufactured from a chrome-steel alloy (Remanit).

Special metal-graphite alloys are used for the carbon

brushes, depending on load capacity.


Power range


→ Voltage 2,000 to 13,800 V



→ Protection type IP 23/W24/R54/55

→ Cooling type IC 01/31/611/81W

→ Mounting IM B3 and IM V1/V10

Applications

→ Ball/roller mills

→ Crushers

→ Rolling mills

→ Shredders

→ Ventilators

→ Refiners

→ Conveyor drives

Accessories

All EMZ high-voltage motors can be equipped with a

wide range of accessories:

→ Pt100 resistance thermometers for winding

and bearing

→ SPM detectors

→ Bentley Nevada vibration monitoring

→ Anticondensation heating elements

→ Contact thermometer

→ Vibration monitoring 4–20 mA

→ Star point terminal box

→ Current transformers for differential protection

→ Tachometer generators

→ Water-leakage monitoring

→ Slip-ring compartment lighting

→ Pressure switch for filter monitoring

1,950 kW slipring rotor ASL 560-06 for a coal-mill drive in a steel works. 3,500 kW slipring rotor ASL 710-06, 11,000 V, 50 Hz drive for a

cement ball mill.

02 | Modular Series

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Customised solutionsThanks to our years of project experience, we can offer

you comprehensive technical advice and assistance for

your drive solutions. From development to construction,

manufacture to operation, we guarantee a standard of

quality for our products and service that will convince

you of our expertise.

→ 100 % identical replicas for existing drives

→ Special designs for specific drive applications

→ High efficiency owing to the use of

loss-optimised materials

→ Project management including installation,

commissioning and training

EMZ Engineering

100 % interchangeable replicas for existing motors

Based on our experience and the numerous successfully-

completed projects, we guarantee an all-round service

when you require replaceable spare motors.

→ Accurate recording of the actual state of the

application in your facility

→ Comparison with current requirements

→ Development of a suitable concept

→ Detailed co-ordination of construction and

accessories

→ Routine and type testing according to

IEC/EN 60034-1

→ Installation, commissioning and training


Hydrostatics

To ensure the adequate lubrication and safe operation

of sleeve-bearing motors, the rotor must rotate in the

bearing shell with a minimum speed that is based on

the bearing size and the revolution. If the minimum ro-

tation speed for specific applications falls below what

is required, the oil film can tear and destroy the sleeve

bearing.

By using a rotation-speed independent hydrostatic unit,

the rotor shaft in the bearing shell is lifted with a pres-

sure of 80 to 150 bar, thus ensuring a safe and wear-

and-tear-free operation at very low rotational speeds

and when starting up.

The hydrostatic units can be connected independently

from a central oil lubrication unit directly to the oil

reservoir of the sleeve bearing.

Special applications

→ Stator windings with executed star point for

Star-Delta starting

→ Constructions for reduced starting currents

→ Double-cage designs for increased starting

torque and heavy start-up conditions

→ Noise-reduced designs with air inlet and

outlet muffler

→ Reinforced housing and bearing designs for use

with shredders with a maximum vibration

level of 28 mm/s

Slide bearings with hydrostatic port. 8,350 kW slipring motor ASL 1120-08 for a sinter fan in a steel plant.

03 | Special Designs

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Resistance startersThree-phase resistance starters are connected to

the rotor circuit of the motor to start asynchronous

machines with slipring rotors. According to the slip-

dependent reduction of the starting resistance and de-

pending on the counter torque, the motor will acceler-

ate with a defined starting torque.

Starter for three-phase high-voltage motors

Liquid starters

The liquid starter is a continuously-adjustable resistor

with a three-phase electrode system which is moved in

an electrolyte. Through the concentration of the electro-

lyte, the starter resistance can be changed and the start-

er optimally adjusted to the respective load conditions.

Oil-cooled drum starters

The oil-cooled drum starter consists of individual cast

iron resistance elements which are manufactured ac-

cording to the required resistance parameters and

mounted in an oil reservoir.

Liquid starters with short-circuit contactor

and circulation pump.


Soft startersOur electronic soft starters allow a controlled reduc-

tion of the starting current and the start-up torque

when starting cage rotors.

Power range

→ Performance max. 16,000 kW

→ Nominal voltage 1,500 to 15,000 V

→ Nominal current 60 to 2,000 A

Medium-voltage soft starters

Technical Data

→ Vacuum contactor

→ Vacuum bypass contactor

→ Control voltage: 110 V - 220 V AC, 110 V DC

→ Motor-protection relay (MSR)

→ Current and voltage transformers

→ Multifunction display (DMA)

→ Soft start and soft stop

→ Current limiting

→ Pump control programmes

→ Adjustable torque and current characteristics

→ Dual setting

→ Boost start (high starting torque)

04 | Soft Starters & Resistance Starters

Start-up 6,000 V soft starter.1,500 kW; 6,000 Volt soft starter.

20

ApplicationsMedium-voltage frequency converters are used in ap-

plications where powerful speed control is required

and where low-voltage frequency converters have

reached their economic and technological limits. With

these, the rotation speed and the torque of asynchro-

nous and synchronous machines are optimally adapted

to suit the actual requirements; energy consumption is

optimised and the CO² emissions reduced.

Medium-voltage frequency converters are used in

many areas:

→ Energy industry

→ Water-resources industry

→ Open-cast mining

→ Oil and gas industry

→ Metal industry

→ Building materials’ industry

Medium-voltage frequency converters

Advantages

By using medium-voltage frequency converters the

copper content in the connecting leads can be reduced

by up to 80%, in comparison to a low-voltage solution.

The space requirement for the supply lines, the instal-

lation costs and the power dissipation of the connect-

ing cables used and, ultimately, the cooling costs, will

reduce – while efficiency increases.

Thanks to substantial energy savings, medium-voltage

frequency converters have very short payback periods.

We provide ready-to-use solutions for voltage ranges

from 2.2 kV to 11 kV with an power of approximately

250 kW to a maximum of 30 MW.

Medium-voltage frequency converters

Used with permission of Rockwell Automation, Inc.


Technical designs

You do not need to do without the usual frequency-con-

verter intelligence. Different applications and designs

are possible:

→ A synchronised bypass of a start-up converter

for consecutive hauling-up of various motors

→ The design with air and water cooling

→ Multilevel technology

→ Operation in weak field areas

→ Operation of standard high-voltage motors in

combination with “Direct to Drive” technology

Even if a power unit fails, the frequency converter can

still operate – but with a reduced output current and re-

duced efficiency.

Depending on the feed and intermediate-circuit technol-

ogy used, international standards such as UL, CSA, IEEE,

GOST are maintained.

We use applications for:

→ Pumps

→ Compressors

→ Extruders

→ Mixers

→ Fans

→ Mills

05 | Frequency Converters

Frequency converter 1.2 MW Multilevel frequency converter 2,000 kW; 6,600 Volt.

22

SG seriesSynchronous machines of the SG series are especially

economical because of low maintenance costs, opera-

tional safety and high efficiency.

Our wide range of synchronous generators is fitted with

a brushless, electronically-controlled DC excitation as

standard. The electronic voltage control ensures opti-

mum voltage accuracy and an excellent dynamic op-

erating behaviour. A design with static exciter and slip-

rings is available on request.

Depending on your requirements, we manufacture syn-

chronous machines for indoor and outdoor installation

with mounted air/air or air/water heat exchangers.

Three-phase synchronous machines

Power range

→ Performance 250 to 35,000 kVA

→ Voltage 2,000 to 13,800 V



→ Protection type IP 23/R54/55

→ Cooling type IIC 01/31/611/81W

→ Design IM B3 and IM V1/V10

Applications

→ Industrial power plants

→ Hydropower plants

→ Test field applications

→ Compressor drives

→ Pump drives


Other EMZ catalogues:

→ EMZ Reference Catalogue

→ EMZ Image Brochure

→ EMZ Low-Voltage Motors’ Catalogue

→ EMZ High-Voltage Motors’ Catalogue

Catalogue request

eMail: [email protected]

Would you be interested in further EMZ catalogues?

If you are, please visit our website at www.emz.de.

All catalogues and references are available to download

in our “Download” section or as a printed edition.

EMZ catalogues


06 | Synchronous machines

Let us convince you of our expertise;

take a look at our reference catalogue!→

EMZ Product Portfolio: Electric motors (for high and low voltage) → Three-phase squirrel cage motors up to 15,000 kW

→ Three-phase slipring induction motors up to 15,000 kW

→ DC motors up to 2,500 kW

Gear motors → Helical-gear motors

→ Worm-gear motors

→ Bevel-gear motors

Transformers (for high and low voltage) → Oil-filled transformers up to 20,000 kVA

→ Cast-resin transformers up to 6,000 kVA

→ Dry-filled transformers up to 1,000 kVA

Power electronics → Frequency converters

→ Inverters

Contact: EMZ Elektro-Maschinen-Zentrale GmbH

Richardstrasse 70

45661 Recklinghausen, Germany

Phone: +49 2361 -6909 -0

Fax: +49 2361 -6909 -99

Web www.emz.de

eMail [email protected]

NEWwww.emz.de

EMZ product configurator→ Configure your products to suit your individual requirements

→ View current stock availability

→ Detailed technical information, dimension tables1and photos of every product

→ Review your order, including delivery status

Documents

EMZ high-voltage motors & drive systems - EMK- · PDF fileEMZ high-voltage motors & drive systems ... AKD/L/W squirrel-cage rotors ... 450, 500 and 560 mm and can be manufac