A Regal Brand www.regalbeloit.com Unipak 2 CACA/CACW High Voltage A C Induction Motors Vertical UNIPAK2 Motor
A Regal Brand
www.regalbeloit.com
Unipak 2 CACA/CACW
High Voltage A C Induction Motors
Vertical UNIPAK2 Motor
2
One of India's most modern motorfactories, incorporating extensive CADfacilities with over 50 years' experiencein the design and application ofinduction motors, enables MARATHONElectric to offer the benefits of provensolutions :
— MARATHON Electric has over2500 MW installed world-wide.
— Upto 4000 KW range capability.
— All speeds available.
— Highest available efficiency - rapidpay-back.
— High Power Factor - Low PowerCost.
— 20 years' expected design life at1000 starts per year
— Resivac VPI Insulation System fortotal winding reliability.
— Highes t qua l i ty - lowes tmaintenance costs.
— Low Noise Level - Bet terperformance than IS:12065.
— Low vibration level - conforms toIS:12075.
— IP 55 enclosure protection asstandard on enclosed machines.
— Factory fixed Air Gap.
— Compliance with National andInternational Standards.
— Built to type N requirements.
— Upto 11 kV, 50 or 60 Hz. supply.
— Low Starting Current designavailable.
— Variable speed drive compatibility.
— Horizontal mounting.
— Rolling or Plain Bearings.
— Environmentally friendly motorsto meet all drives.
— Type “e” version available onrequest.
— Slipring version available.
Unipak2
3
Standards and Specifications
Compliance with the InternationalStandard IEC 34 ensures that motorsalso meet the requirements of othera l igned Nat iona l S tandardsincluding :
IS:325 INDIANBN 7 : 1963 BELGIUMNF C 51-111 FRANCEVDE 05301/1.66 GERMANYCEI 2-3, N. 355 ITALYNEN 3173 NETHERLANDSNEN 41.69 NORWAYSEN 2601 01 SWEDENSEV 3009 SWITZERLANDB5 4999 & 5000 UNITED
KINGDOM
Compliance with other specificationsand standards such as NEMA-MG1and API 541 can be offered, andfurther major user specifications canbe met on request. Please check withour sales department of the addressgiven on the back of this publicationfor more detailed information.
Many company and pro jec tspecifications use IEC 34.1 as a basisor reference and thus compliance maybe asured.
Cooling MethodsAir-cooled CACA (TEAAC) IC 0161,Water-cooled CACW (TEWAC) ICOA1W7, Open Ventilated (OVDP) IC01, and NEMA II enclosures areavailable as standard options.
Mounting ArrangementsHorizontal Foot Mounting to IM 1001& Vertical Mounting to IM 3011.
DimensionsShaft and fixing dimensions are inaccordance with the requirements ofIEC 72 and 72A together withBS 4999 part 141 & IS:8223.
Frame SizesShaft centre heights from 400 to 710mm are covered.
SpeedsAll fixed speed requirements can be
met, together with machines forvariable speed drive systems. Provendesigns exist for most driven equipmentneeds (e.g. compressors, pumps, fans,crushers and mills).
Electrical SupplyAll National and International supplyvoltages and frequencies are cateredfor by the Unipak range.
InsulationUnipack Class F Resivac Vacuum andPressure Impregnation Insulationsystems comply with IEC 85. Afterimpregnation the stator windings aresubjected to the voltage tests specifiedin IEC 34.1. All machines are subjectto loss tangent tests.
Degree of Protection byEnclosureIP 55 as standard for totally enclosedwater or air cooled machines.Protection and enclosure types are asrecommended by IEC 34-5 & IS:4691.
Cooling MethodMethods o f coo l ing are asrecommended by IEC 34-6 (completesystem) & IS:6362.
VentilationThe designs employ radial ducted
ventilation using shaft mounted steelfans to circulate the internal coolingair. CACA (TEAAC) motors are fittedas standard with high efficiency, uni-directional low noise level, shaftmounted steel fans.
Noise LevelParticular attention has been given toall sources of noise generation andUnipak standard designs meet the moststringent modern requirements, (i.e.typically 85 dB (A) at 1 metre).
VibrationUnipak motors comply with therequirements of API 541, andIS:12075. Rotors are dynamicallybalanced prior to assembly in twoplanes. Vibration is then checked ontest before and after overspeed teststo prove stability.
EfficiencyTypically, full load efficiencies greaterthan 96% are achieved as standardensuring low operating costs.
Starting CurrentStandard designs are within BS 4999Part 112 design D limits. Lower startingcurrent designs can be tailored to suitspecific supply system limitations whererequired.
POWER OUTPUT
KW
VOLTAGE
POLES(REV/MIN)
3300 6600
2(3000)
3300 6600
4(1500)
3300 6600
6(1000)
3300 6600
8(750)
3300 6600
10(600)
3300 6600
12(500)
40003600320028002400200016001200800400
NOTE : FOR 11 KV , PLEASE REFER TO WORKS
4
FramesUnipak Motor frames are of boxconfiguration, manufactured from castiron or Fabricated Steel, thus ensuringan extremely robust and rigid supportstructure. The top of the frame has arectangular opening to allow fitmentof the air/air or air/water heatexchanger, or alternative ventilationarrangements.
Stator and Rotor Cores
Stator core packs are built onexpanding mondrels using packets ofinsualted, low-loss laminated electricalsteel, interspersed with I-beam spacersections which form radial coolingducts. Cores are hydraulicallycompressed between substantial steelend-plates and the entire assembly issecured by sequentially weldinglangitudinal steel core-bars to the backof the laminations and the end-platesto maintain the pressure. The core barsextend beyond the end plates to formrigid anchorages for bracing of theend windings.
Rotor cores are built against acompression plate utilising packets ofinsulated laminations in a similarmanner to the stator cores. These arethen shrunk onto the shaft assemblyand retained by circumferential keys.
Rotor Cage WindingsRotor bars are designed andmanufactured to maintain a tight fitthroughout the slot length and depth,and are connected to the end-rings bymeans of a specially developed one-shot brazing process ensuring totalreliability throughout the life of themotor. Cage designs are optimised toensure a minimum starting capabilityof 1000 starts per year over a 20-yearperiod.
Construction
5
Stator CoilsAl l Unipak s ta tor Coi l s aremanufactured from annealed copperstrip, insulated with mica-paper tape.Loops are formed withthe appropriatenumber of turns, and the coil is thenpulled into the required shape in aforming machine. Layers of mica tapeinsulation are then added, followedby the application of corona shield orsemi-conducting tape as appropriateto the supply voltage.
The coils are inserted into their slots inthe stator core pack and fixed firmlyin posit ion with slot wedges.Endwindings are securely braced, thusensuring the prevention of movementduring starting and service.
High voltage tests are carried out bothbefore and after connection, and againafter impregnation in order to checkinsulation integrity. On completion ofthe winding process, resistances andimpedances are checked for balanceand design conformly.
End Winding BracingThe end winding bracing system isdesigned to match the rotor capability
of a minimum 1000 starts per year for20 years and to withstand the stressesinvolved in 180 degrees out-of-phasereswitching.
Winding Impregnation
The RESIVAC Vacuum PressureImpregnation System (VPI) is employedon all Unipak Motors. This systemensures global impregnation of theentire wound stator core assemblyusing a specially developed solventlessepoxy resin. The process guaranteesthat all air and moisture is extractedunder vacuum from the winding beforepressure then forces resin into everyvoid within the assembly.
Curring of the resin is carried out whilstconstantly rotating the assembly in onoven to ensure even distribution. Theentire impregnation operation ismicroprocessor controlled and datalogged to ensure total reliability of thewindings during ser vice l i fe.
6 7
TYPICAL TERMINAL ASSEMBLY
UNIPAK 2 CACA TYPICAL SECTION
GASKET GLAND PLATECOVER PLATE
GASKET
TERMINALS
TERMINAL RAIL
FRAME POCKET
HEATER LOCATION AT EACH END OF FRAME
GASKET
COVER PLATE
FRAME BASE
FAN BAFFLE
GASKET
COVER PLATE
HEATER
STATOR COREPACK PRIOR TO WINDING
CORE END-PLATE
CORE-BAR
LAMINATIONS
SPREADING CHAMBER
TERMINAL BOX
INTERNAL FAN
ROTOR SHAFT
SHAFT SEAL
D.E. ENDBRACKET
FLINGER
BEARING
SATOR FRAME
C.A.C.A. COOLER N.D.E. ENDBRACKET
INLET MESH
FAN INLET EYE
FAN COWL
EXTERNAL FANINNER CAP
COPPER ENDRING
COPPER BAR
LAMINATIONS
CACW Cooler
8
Curring of the resin is carried outwhilst constantly rotating the assemblyin on oven to ensure even distribution.The entire impregnation operation ismicroprocessor controlled and datalogged to ensure total reliability of thewindings during ser vice l i fe.
ShaftShafts are manufactured from carbonmanganese steel bar material of grade150M19 to BS970. Welded-onlongitudinal arms are utilised. Standardmotors have a single parallel shaftextension. Where appropriate, motorsmay utilise forged shafts and integralhalf-couplings.
Bearings and LubricationPlain white metal or rolling elementendshield-mounted bearings areavailable to suit appropriate motorapplication and speed.
Plain bearings incorporating speciallydeveloped multiple labyrinth floatingoil and air-seals ensure that dynamicchanges of motor internal pressure donot adversely affect the lubricationsystem and allow IP55 degree ofprotection as standard. Centre flangebearings are used on larger machinesgiving considerable benefits ofimproved rotor dynamic performanceand overall motor efficiency. Plainbearings are insulated at the sphericalseating on both bearings, enablingsimple testing of insulation integrity.In operation, an earth connection atthe drive-end avoids any build-up ofvoltage. Either rolling element or plainbearings are available on slower speedmachines and are selected forminimum maintenance and to avoidthe need for external lubricationsystems.
Impregnation Vessel
Bearing arrangement
9
TerminationsFault rated elastomeric connectors(with or without mechanical protection),steel weatherproof boxes, phaseinsulated or fault rated phasesegregated terminal boxes, andterminal boxes including provision of,or for surge diverters, currenttransfarmers etc. can be providedwhere appropriate. Winding neutralterminations may be concealed behinda cover or brought out to an externalchamber to allow for the fitting ofcurrent transformers etc. whererequired. Terminal boxes can beprovided on either side of the machine,and are able to accept cable entryfrom any of 4x90 degree positions.
Paint SystemSurfaces are degreased, then blastcleaned to ISO 8501 and ISO 8503,which deline surface cleanliness androughness. Surfaces are then primedusing a modified synthetic resin redoxide primer to a dry film.
A single finish coat of two pack EpoxyPoint is applied.
Auxiliaries
Anti-condensation heaters meet typeLN requirements as standard and areeasily withdrawable for maintenancewithout dismantling the motor. Bearingtemperature, viberation monitoring,cooling system performance isavailable as required.
Line 0,2-0, 5µs greater than 1.0µsVoltage wavefront wavefront
kV kV p.u.* kV p.u.*
3.3 13.47 5 18.86 7
4.16 17.00 5 23.77 7
6.6 17.00 3 32.33 6
11.0 26.94 3 49.39 5.5
13.2 32.33 3 59.27 5.5
13.8 33.80 3 61.96 5.5
Impulse withstand levels for standardResivac stator windings.
(*p.u.=per unit; 1 p.u. is equal to thepeak value of the phase voltage.)
Total QualityWe are manufacturing complete rangeof HT motors with quality assuranceplan endorsed by major consultantsof our country. Also over principalsof Rugby had laid down stringentacceptance norms in each stage ofproduction for the above motors. Allimput materials are critically tested in-house as per National/Internationalstandards to ensure error free endproduct.
Full range of Unipak motors are routinetested at rated voltage and power inour test plant. Type testing can bedone upto 4000 KW, 11KV, 4 pole.
Our customers are welcome to beassociated during stage inspection orfinal inspection during manufactureof every stage.
Graph of winding capacitance to earth during the impregnation processshowing the shart increase when preasure is applied.
DRYVACUUM
WINDINGMMERSED
IN RESIN
FIRST STAGE OFPRESSURE CYCLE
STABILITY ANDCONTINUATION OF
PRESSURE CYCLE
CAPA
CITA
NCE
TIMES HOURS
Phase segregated Terminal Box
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217
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EA
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355U
710
610
710
355
125
710
894
722
704
838
673
533
200
120
8065
140
119
355
3813
1128
2282
859
670
355U
900
610
900
355
125
710
894
722
704
838
673
533
200
120
120
6514
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935
538
1311
2823
9087
567
0
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800
686
800
475
156
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1010
778
760
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590
240
150
8585
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2760
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1000
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590
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8517
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540
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3528
6910
3575
0
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900
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162
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833
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784
646
260
150
110
100
210
174
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2989
1150
830
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1120
750
1120
500
162
908
1125
833
815
949
784
646
260
150
110
100
210
174
450
4517
1135
3189
1230
830
500U
1000
850
1000
530
203
1042
1270
906
888
1022
857
719
260
160
100
120
210
194
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4518
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3225
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3445
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1510
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6610
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056
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2150
4235
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1510
75
NO
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FOR
GA
DRAW
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ABO
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60 M
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R HE
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, PLE
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WO
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11
Uni
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2 O
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ll Di
men
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s
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MA
CEG
BTE
RMIN
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BOX
WH
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X 9
0° A
DA
PTO
RFI
TTD
AD
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78m
m T
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FOR
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∅D
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POLE
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SG
ENER
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DIM
ENSI
ON
S
FRAM
EA
BC
AAAB
ACAD
AD1
AD2
AD3
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BBBC
DE
EDH
HAHC
KL
TBX
355U
710
610
710
254
125
710
894
722
704
838
673
533
200
120
8095
170
155
355
3813
1128
2016
788
670
355U
900
610
900
254
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894
722
704
838
673
533
200
120
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9517
015
535
538
1331
2821
2380
467
0
400U
800
686
800
280
156
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1010
778
760
894
729
591
240
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021
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440
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1000
686
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778
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894
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150
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194
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2307
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900
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315
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260
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176
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1000
850
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906
888
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857
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260
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216
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1250
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335
203
1042
1270
906
888
1022
857
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260
160
100
130
250
216
500
4518
9835
2940
1065
930
560U
1120
950
1120
355
230
1180
1515
1050
1030
1166
1000
890
320
130
130
160
240
220
560
4521
5042
3340
1210
1075
NO
TE :
FOR
GA
DRAW
ING
ABO
VE 5
60 M
M C
ENTE
R HE
IGHT
, PLE
ASE
REFE
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WO
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A Regal Brand
www.regalbeloit.com
Paharpur Works58, Taratala RoadKolkata - 700024Ph: 91 33 4403 0400Fax: 91 33 2469 5369/8530
www.marathonelectric.com
Motors
AEI Works1, Taratala RoadKolkata - 700024Ph: 91 33 4403 0500Fax: 91 33 2469 6988
TM
MEMI/CAT/UNIPAK2/0112/03 Replaces MEMI/CAT/UNIPAK2/1108/02