ABB AMXE250, Manual

Page 1: ... MANUAL Motors for heavy electrical vehicles AMXE250 ...

Page 2: ...l incidental or consequential damages of any kind arising from the use of this document nor shall ABB be liable for incidental or consequential damages arising from the use of any software or hardware described in this document This document and parts thereof must not be reproduced or copied for use for other than that of the AMXE160 without ABB s written permission The contents thereof must not b...

Page 3: ...commissioning 15 3 4 Insulation resistance check 15 4 Motor installation 16 4 1 Preparation and lifting 16 4 2 Installation of coupling 16 4 3 Installation of motor 17 4 3 1 Flange mount 17 4 3 2 Side mounts 17 4 4 Liquid cooling system installation 18 4 5 Electrical installation 19 4 5 1 Connection of power supply 20 4 5 2 Earth point 21 4 5 3 Auxiliary connection 21 5 Operation 22 5 1 Failure mo...

Page 4: ... and storage 12 Figure 4 Position of lifting eye bolts 13 Figure 5 Lifting of the motor 14 Figure 6 Removing the rotor shaft locking device 16 Figure 7 Available installation interfaces seen from D end 17 Figure 8 Position of liquid cooling inlet and outlet 18 Figure 9 Motor electrical connection interfaces 19 Figure 10 Example of typical cable arrangement 20 Figure 11 Connecting the mating power ...

Page 5: ... drive side of motor WARNING signal word used to indicate a potentially hazardous situation which if not avoided can result in death or serious injury Symbols used in this manual Caution risk of electric shock Safety Alert Symbol warns of a potential personal injury hazard Warning magnetic field Prohibition No access for people with active implanted cardiac devices pace maker Warning Magnetic fiel...

Page 6: ...consideration 1 3 Warranty The warranty period is 12 months after commissioning but no later than 18 months from the date of notification of being ready for shipment An extended warranty can be offered on request 1 4 Information on electromagnetic compatibility The user must take the following precautions during installation and operation in order not to impair the electromagnetic compatibility If...

Page 7: ... cleaning agents and the use of lubricants can involve health and or safety hazards The recommended precautions and procedures stated by manufacturers should be followed Non authorized modifications as well as the use of tools components and auxiliary components not corresponding to the installation or maintenance instructions exclude any liability of the motor manufacturer The traction motor has ...

Page 8: ...ease harmonic losses noise and torque pulsations The insulation system contains corona resistant materials has low water absorption properties and complies with temperature class H Standard features options are available 3 phase permanent magnet synchronous motor Inverter adapted design of active material Class H insulation system Temperature sensors inside the stator winding Rotor balance grade G...

Page 9: ...ew of the motor Item no Designation 1 External shaft seal 2 Flange D end shield 3 Nameplate 4 Auxiliary connectors 5 Power supply connectors 6 N end bearing 7 Side mounts 8 Shaft splines 9 D end bearing Table 1 Legend to exploded view Figure 1 ...

Page 10: ... of rotation 5 Mounting code according to IEC60034 7 6 Degree of protection according to IEC60034 5 7 Temperature class of insulation system for the motor according to IEC60034 1 8 Defined duty according to IEC60034 1 9 Connection 10 Motor weight 11 N end bearing 12 D end bearing 13 Maximum rotational speed 14 Variant codes options 15 Product code 16 Stall current 1 17 Back EMF 20 C and rated spee...

Page 11: ... long as the winding temperature does not exceed 180 C As mentioned in the product description the motor is equipped with temperature sensors in the stator winding In most inverters it is possible to set a warning limit and a shutdown limit for based on the winding temperature To not compromise the expected lifetime of the winding the values in Table 3 are recommended Temperature measured by Pt100...

Page 12: ...device should not be removed as long as the motor remains in storage Remove the rotor locking device prior to installation of the motor Figure 3 Rotor shaft locking during transportation and storage 3 1 2 Inspection of delivery Unpacking should be done carefully in order to avoid damage The delivery should be checked against the packing list NOTE When the traction motor arrives at its destination ...

Page 13: ...lifting and lifting hole in the motor are undamaged before lifting Damaged components must be replaced before lifting Lifting must be performed with great care and using appropriate equipment When lifting the motor it is important to lift it in a way that does not affect any critical part such as bearings shaft or connection box There are two holes for each allowed lifting setup where the lifting ...

Page 14: ...MOTORS FOR HEAVY ELECTRICAL VEHICLES 14 The angle between the lifting chains shall be maximum 60 see Figure 5 Figure 5 Lifting of the motor ...

Page 15: ...ved for mating surfaces e g shaft and flange surfaces Tectyl 506 can be removed with Tectyl Biocleaner Tectyl HPS solvent borne thinner vapor degreasing a hot alkaline wash or low pressure steam 3 4 Insulation resistance check Measure insulation resistance before commissioning after long periods of standstill or storage when winding dampness may be suspected Insulation resistance should be used as...

Page 16: ...r shaft and the mating coupling must be accurate The higher the motor operating speed the higher accuracy is needed For side support mounting Some type of flexible coupling shall be used and the geometrical tolerance demands can differ between type and supplier See manual from the coupling supplier For dimensions involving the motor shaft flange and side mounts see the outline drawing The product ...

Page 17: ...ning 4130 016 0032 M16 See outline drawing for further details 4 3 2 Side mounts For side mount interfaces see Figure 7 There are threaded M12 holes along the sides of the motor at 3 12 and 9 o clock The threaded holes have insert Helicoil plus free running 4130 012 0024 M12 See outline drawing for further details The alignment between the side support and the mating surfaces must be accurate in o...

Page 18: ...or equipped with an O ring seal and apply thread sealant Loctite 577 or similar in the internal thread Figure 8 Position of liquid cooling inlet and outlet Recommended coolants are ethylene glycol based such as Antifrogen N from Clariant or propylene glycol based mixed with water The motor design is intended for a mixture of 50 50 Max allowed pressure is 4 bar at inlet connection NOTE Coolants mig...

Page 19: ...s and quantities of the connectors is depending on applicable options of the motor Figure 9 shows an overview of the electrical connection interfaces and additional details in Table 5 Please see circuit diagram 3BSM625000 10 for full details Figure 9 Motor electrical connection interfaces Connector description Type of connector Comment Temperature sensor M12 male 4 pole B coded Temperature sensor ...

Page 20: ...hase U V W All nine power connectors must be connected to power cables when setting the power supply to ON See Power connectors U V and W in Figure 9 NOTE Ensure that the motor is disconnected from power supply prior to connecting or disconnecting the high voltage power connectors NOTE The power supply connectors within a phase are not unique and can be connected to any matching phase on the inver...

Page 21: ...verter or vehicle chassis must be installed in an appropriate way and be suitable for high frequency currents NOTE Ensure that the dedicated surface on the earth point is free from paint and dirt to ensure a good connection 4 5 3 Auxiliary connection The motor is equipped with a number of auxiliary M12 connectors Number and type as per applied options to the motor See Figure 12 for positions of th...

Page 22: ...mation NOTE If the motor is equipped with heating elements in the winding ensure they are electrically connected and powered to prevent possible condensation during standstill 5 1 Failure mode operation Although not recommended the motor may operate for a short term in failure mode operation if this is unavoidable or in an emergency as long as the sensors monitoring the stator winding temperature ...

Page 23: ...Wait for hot components to cool down before starting the work Warning pressure The liquid cooling system may be pressurized Warning Magnetic field Hazard for strong magnetic field Prohibition limited access No access for people with active implanted cardiac devices pacemaker NOTE Only skilled and trained personnel should carry out maintenance When carrying out any work on electrical conductors the...

Page 24: ...whether problems are beginning to develop before they can cause failures and unscheduled maintenance breaks The visual inspection shall include the following areas 1 Listen for any abnormal noise or increased vibrations 2 Verify that the liquid cooling system connections for inlet and outlet are free from dust or any parts that block the flow If required clean the inlet and outlet areas Check that...

Page 25: ... external shaft seal on the D end see Figure 1 The expected lifetime of the seal is dependent on the motor duty cycle and the external environment Check for wear and replace if necessary A damaged external shaft seal might compromise the IP class of the motor NOTE The external shaft seal should never run dry lubricate if necessary 6 2 5 Shaft spline Inspect the shaft splines see Figure 1 to ensure...

Page 26: ...nimum of 80 cm from the surface of the motor Caution must be taken during cleaning so that liquid is not forced inside the motor Do not direct the nozzle directly toward the following areas of the motor The external shaft seal Connectors connection box and edges around connection box cover 6 2 7 Touch up painting The motor is painted with corrosion resistant paint color RAL 9005 Temabond ST300 is ...

Page 27: ...is only valid if recommended spare parts are used For information on price and delivery times please contact your local ABB sales office 7 2 Consumables Following consumables are foreseen to be needed Type Description ABB Part number Tectyl 506 Corrosion preventive compound 12410011 108 Temabond ST300 Fast drying single coat alkyd paint FAST ECO Dielectrical fluid for cleaning NEUTRA PON Alkaline ...

Page 28: ...ign particles in the air gap Please contact ABB for further instructions Motor starts with abnormal permanent scraping noise Rotor and stator touch each other in the air gap Please contact ABB for further instructions Motor is abnormally hot also at no load Liquid cooling system is out of order Check liquid cooling system s functionality High vibrations at run out Too high residual unbalance Pleas...

Page 29: ...trical fault Motor current is abnormally high Fault in the stator winding Measure the winding resistance between the stator terminals Motor has different phase currents and gets high temperatures Asymmetrical feeding Check the similarity of the phase voltage on the incoming cables Motor gets an abnormally high phase current and high temperature also at no load Wrong incoming voltage level Correct ...

Page 30: ...ing In most countries the permanent magnets are not considered as hazardous waste and thus the motor can usually be disposed in the same manner as an induction motor Please check the local laws and regulation and contact your local ABB sales office for more information ...

Page 31: ...Final comment 31 10 Final comment If you have any questions regarding environmental matters not taken up in this instruction please contact the ABB after sales ...

Page 32: ... the correct tighten torque Has thread locking been applied to the bolts Has the spline been lubricated with a suitable molybdenum disulfide grease Liquid cooling system installation Are recommended mating cooling connectors used Is a recommended coolant used Are the requirements of the liquid cooling system according to the separate rating plate fulfilled Electrical installation Are the mating HV...

Page 33: ... For more information and contact details www abb com motors generators 3BSM625000 11 Rev A EN 06 2022 ...