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MANUAL

Motors for heavy electrical vehicles

AMXE160

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Summary of Contents for AMXE160

Page 1: ... MANUAL Motors for heavy electrical vehicles AMXE160 ...

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: ...tallation in vehicle 16 4 1 Mechanical installation 16 4 1 1 Preparation and lifting 16 4 1 2 Installation of coupling 16 4 1 3 Installation of motor in vehicle 17 4 2 Liquid cooling system installation 18 4 3 Electrical installation 19 4 3 1 High voltage connection 19 5 Operation 21 5 1 Failure mode operation 21 6 Inspection and maintenance 22 6 1 Safety Instructions 22 6 2 Inspection and Mainten...

Page 4: ... on a pallet 12 Figure 5 Position of lifting eye bolts 13 Figure 6 Lifting of motor 14 Figure 7 Geometrical tolerances for the mating coupling for B14 and B5 mounting 16 Figure 8 Max allowed height difference between D end and ND end 17 Figure 9 A threaded hole including inserted Heli Coil 17 Figure 10 Position of liquid cooling inlet and outlet 18 Figure 11 Connection box at delivery and location...

Page 5: ...ve 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 Safety Alert Symbol warns...

Page 6: ...into 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 precautions during installation and operation in order not to impair the electromagnetic compatibility If it is ne...

Page 7: ...as 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 motor has rotatin...

Page 8: ...ame Special efforts have been made to decrease 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 insid...

Page 9: ...nation 1 External shaft seal 2 End shield DE 3 Stator frame 4 Rating plate 5 Separate rating plate with liquid cooling system data 6 End shield NDE 7 Connection box 8 DE bearing 9 Shaft 10 NDE bearing Figure 1 Exploded view of the motor ...

Page 10: ... default phase order Seen from D end 6 Type designation 7 Maximum ambient temperature 8 Temperature class of insulation system for the motor according to IEC60034 1 9 Degree of protection according to IEC60034 5 10 Serial number 11 Rated voltage 12 Connection 13 Rated frequency 14 Rated power 15 Rated speed 16 Rated current 17 Rated power factor 18 Defined duty according to IEC60034 1 19 Back EMF ...

Page 11: ... 2 is the continuous operation point S1 Operating in this point will not compromise the expected lifetime As a simplified method the S1 power in a duty cycle can be calculated by the root mean square method 𝑃𝑃𝑃𝑃𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 1 𝑇𝑇𝑇𝑇 𝑀𝑀𝑀𝑀𝑖𝑖𝑖𝑖 2 𝜋𝜋𝜋𝜋 𝑛𝑛𝑛𝑛 60 𝑖𝑖𝑖𝑖 2 𝑇𝑇𝑇𝑇 𝑖𝑖𝑖𝑖 1 𝑛𝑛𝑛𝑛 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝑟𝑟𝑟𝑟𝑠𝑠𝑠𝑠𝑟𝑟𝑟𝑟 𝑀𝑀𝑀𝑀 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑟𝑟𝑟𝑟𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑠𝑠𝑠𝑠 𝑁𝑁𝑁𝑁𝑟𝑟𝑟𝑟 𝑇𝑇𝑇𝑇 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 𝑡...

Page 12: ...ree surface Figure 4 The motor is delivered on a pallet 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 motor arrives at its destination be sure to check the motor in order to determine possible transport damage as quickly as possible Any damage during delivery or deviations from the pack...

Page 13: ...g Damaged lifting eye bolts 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 the bearings shaft or connection box There are two holes for each allowed lifting setup where the lifting eye bolts should be attached The positions are shown i...

Page 14: ...MOTORS FOR HEAVY ELECTRICAL VEHICLES 14 The angle between the lifting chains shall be a maximum of 60 see Figure 6 Figure 6 Lifting of motor ...

Page 15: ...t corrosion protection coating is removed 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 I...

Page 16: ...or the mating coupling for B14 and B5 mounting The values for X and Y depending on motor operating speed could be found in Table 3 Operating speed rpm Concentricity X Perpendicular Y Non flexible coupling Flexible coupling Non flexible coupling Flexible coupling 0 2000 0 13 0 25 0 001 0 002 2000 3000 0 10 0 20 0 0008 0 0016 3000 4000 0 07 0 15 0 0006 0 0012 4000 5000 0 05 0 1 0 0004 0 0008 Table 3...

Page 17: ... damaged the alignment between the side support and the mating surfaces must be accurate The figure below illustrates the max allowed height difference between the D end and ND end To achieve this shims between the side support and the mating surfaces can be used Figure 8 Max allowed height difference between D end and ND end Recommended tightening torques can be seen in Table 4 Thread size Grade ...

Page 18: ...d Figure 10 Position of liquid cooling inlet and outlet Recommended coolants are ethylene glycol based such as Antifrogen N from Clariant or propylene glycol based NOTE Coolants might be a toxic compound Use correct personal safety equipment and avoid exposure to the coolant Information about pressure drop as a function of flow rate and how glycol mixture affects performance is found in the motor ...

Page 19: ...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 High Voltage Touching a live motor connection causes serious injuries or death The motor is equipped with a high voltage power connector see Figure 1 NOTE Ensure that the motor is disconnected from power supply prior to con...

Page 20: ...d location of earth points The earth cable from the inverter or vehicle chassis must be installed in an appropriate way and be suitable for high frequency currents NOTE Ensure that the dedicated surfaces on the earth points are free from paint and dirt to ensure a good connection ...

Page 21: ...ally connected to prevent possible condensation during standstill NOTE Operating in conditions below 20 C without proper options risks damaging critical mechanical components such as bearings internal and external seals etc 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 se...

Page 22: ... Hot Components Risk of burns caused by hot components Wait for hot components to cool down before starting the work Warning Magnetic field Prohibition No access for people with active implanted cardiac devices pacemaker Warning The liquid cooling system may be pressurized NOTE Only skilled and trained personnel should carry out maintenance When carrying out any work on electrical conductors the l...

Page 23: ...ased 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 there are no fluid leakages The pressure drop may not exceed the rating on the separate rating plate see Figure 3 3 Verify that the temperature sensors in the stator winding are functioning properly NOTE...

Page 24: ...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 3 5 Shaft spline Inspect the shaft splines see Figure 1 to ensure no excessive wear has occurred and apply a suitable molybdenum disulfide grease to the splines 6 3 6 External cleaning Extern...

Page 25: ...nozzle too close to the surface a minimum 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 Connection box and edges around connection box cover 6 3 7 Re painting The motor is painted with corrosion resistant paint color RAL 9005...

Page 26: ...and dirt free storage The parts must be stored in a heated room where the temperature variations are small For information on price and delivery times please contact your local ABB sales office Consumables 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 Alka...

Page 27: ...rsonal injury hazard Warning magnetic field Prohibition No access for people with active implanted cardiac devices pace maker Warning High Voltage Touching a live motor connection causes serious injuries or death The motor must be isolated from the power supply system prior to carrying out any investigations Mechanical failures Failure Possible cause of failure Corrective action Motor is vibrating...

Page 28: ...lt If not it is an electrical 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...

Page 29: ...nce the traction motor mainly is assembled with screws and nuts it is rather simple to carry out the dismantling When the traction motor has been dismantled into its different components the different components have to be separated and grouped together depending on material types 9 2 1 Normal carbon steel The following components are separated into one group for normal carbon steel Bearing cover ...

Page 30: ...ted in the actual components and require some effort in order to be separated There are some special tools available to help separation but normally wedges large hammers gas burners and manpower is used The following components are separated into one group for copper Stator coils Stator connection Connectors Ni plated brass 369 370 371 315 9 2 7 Non metallic Parts in winding Parts in connection bo...

Page 31: ... TEMABOND ST300 is to be considered as hazardous waste and must be taken care of according to regulations 9 3 1 Permanent magnets Magnets are of type Samarium Cobalt For information regarding how to recycle them please contact your recycling company 9 3 2 Final comment If you have any questions regarding environmental matters not taken up in this instruction please contact the ABB after sales ...

Page 32: ...h 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 H...

Page 33: ...Introduction 33 ...

Page 34: ... For more information and contact details www abb com motors generators 3BSM066221 EN 04 2022 ...

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