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TEFC Motors

ENERGY EFFICIENT MOTORS LEVEL 2

	Energy Efficiency level 2 as per IS:12615
	Energy Efficiency as per CEMEP Standards prevalent in Europe
	'V' seal arrangement up to 355 frame - Easier assembly of bearing housing
	Integral bearing cover with endshield up to 225 frame
	Larger terminal box for accommodating bigger Aluminium cables
	Sophisticated CNC Machines, Most Advanced Manufacturing Technology & Test Plant - Improved reliability.

STANDARD SPECIFICATIONS


RANGE	0.18 kW to 400 kW (FRAME 63 to 400) Multi speed options are also available
VOLTAGE	415 V +/- 10 %
FREQUENCY	50 Hz +/- 5 %
COMBINED VARIATION	+/- 10 % (ABSOLUTE SUM)
INSULATION	Class 'F' (Temp. rise limited to class 'B' ) as standard
AMBIENT / TEMPERATURE RISE	50⁰C / 70⁰C
DEGREE OF PROTECTION	IP55 AS PER IS: 4691

SPECIAL DESIGNS OFFERED

ELECTRICAL		MECHANICAL
Non Standard Voltage And Frequency Variation		Non Standard Mounting Dimensions
Duel Voltage Triple Voltage		Special shaft Extension
Inverter fed Supplies And AC Variable Speed drives		Double shaft Extension
Energy Efficient Motors		Low Vibration & Noise Level
High Slip Motors		Shock Grade Motors
Motors For Frequent starts/stops/reversals (e.g. crane duty)		Motors for Hazardous areas
Torque Motors		Motors For Dust Laden Atmosphere
High Frequency Motors		Brake Motors
Textiles Motors		Canopy for horizontal mounting motors
10,12,16,18,24,32 Pole Motors		Special Bearings like Thrust Bearings
Special Performance Requirements		Tacho Mounting
Class H insulated Motors		Non Standard Paint Shade and Painting Procedure for required Dry Film Thickness
Motors With Service Factor		Fabricated Steel Enclosure Alternate Terminal Box Position
Slipring Motors with Bar-wound rotors for Frames 280 to 400		Special Shaft Material
Motors for operation on Variable Frequency Drive - Refer note on next Pages		Stainless Steel/ Brass Hardware Accessories like Resistance Temperature Detectors, Bearing Temperature Detectors, Thermocouples, Plug & Socket
		Custom Size Fabricated terminal box & Terminal Arrangements.

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Energy Efficient Motors

ENERGY EFFICIENT MOTORS LEVEL 1
	Crompton Greaves has now developed a complete family of high efficiency motors confirming to Eff level 1 standards of IEEMA : 19-2000 and other applicable standards in Europe and rest of the world. These motors are available in TEFC construction for use in safe areas and also in flameproof enclosure for use in Hazardous areas.

SPECIAL DESIGN FEATURES :
	Higher efficiencies are achieved by following special features : • Low loss special grade of thinner laminations. This reduces the Iron loss even at partial loads. • Thicker conductors and more copper contents reduce copper loss due to lower resistance. • Longer core length, reduced and uniform air gap between stator and rotor to reduce stray losses . • Special design of fan and fan cover to reduce windage losses.

BENEFITS :
Improved efficiency is available from 60 % to 100 % load. The eff curve is almost flat resulting in higher energy savings as in most of the cases the motor is not always fully loaded . The special design features also result in lower operating temperatures which enhance the life of motor and reduce the maintenance costs. These motors have inherently low noise and vibration and help in conservation of environment . Crompton Greaves energy efficient motors offer an additional feature which no other manufacturer offers. These motors are with highest power factor in the industry due the special exclusive designs available with Crompton Greaves. The higher power factor reduces the currents in the cables supplying power to motor and this reduces cable loss, improving the system efficiency sometimes by even 2 %. Sometimes this allows even a lower cable size saving tremendously on capital costs. Saving is also made by reducing capacitors required to improve power factor.

MANUFACTURING RANGE :
Efficiency Level 1 • 0.37 kW to 160 kW • Frame sizes : 71 to 315 for TEFC 80 to 315 for Flame proof • The entire range is available in IEC frames sizes (metric range) and also in NEMA frames

CONFORM TO FOLLOWING STANDARDS :
• IEEMA : 19-2000
• IS 12615
• IS 325-1996 & IEC 60034
• NEMA EPACT EFFICIENCY VALUES (for NEMA motors) IEEMA 19-2000 standard covers kW ratings only up to 160kW. However we are offering energy efficient motors up to 450 kW.

IMPORTANCE OF ENERGY EFFICIENCY :

Growing cost of energy calls for power saving at each possible step of manufacturing. Electric motor driven systems used in industrial processes consume more than 70 percent of electricity used in industry, hence best possible technology is being applied for achieving highest possible efficiency values.

EFFICIENCY MEASUREMENT OF AN ELECTRIC MOTOR

The efficiency of an electric motor is determined by the amount of useful power it produces compared to the amount of energy required to operate it. The figure below illustrates how a Crompton Greaves Energy efficient motor effectively turns 1000 units of electrical power into mechanical power. Since motor efficiency is commonly expressed as a percentage. Efficiency in this case would be 94%.

ENERGY EFFICIENT MOTORS LEVEL 1
The benefits of using these motors are maximum in continuous duty applications like Blowers, Compressors, Fans, Exhausters Pumps etc.

BEST PERFORMANCE EVEN AT PARTIAL LOADS :
In many applications the load factor of the motor will range between 60% to 80%. The efficiency curve of standard motor is drooping in nature i.e there is a sharp fall in efficiency at partial loads. But the energy efficient motors have a flat efficiency curve and hence the fall in efficiency is marginal. Thus energy saving is significant even in part loads.

INTERNATIONAL APPROVALS CERTIFICATES

ASSESSING COST EFFECTIVENESS OF ENERGY EFFICIENT MOTORS :

Savings :
Savings are calculated as follows :-
kW - out put of motor in kW
E1 - efficiency of standard motor
E2 - efficiency of energy efficient motor

Savings=X *

EXAMPLE

3.7 kW 4 pole motor in frame ND112M
Std motor eff 2: 85 % eff1 88.3 %
Price eff2 : Rs 7215/- eff1: Rs 9380/-
Working hours 16 per day, working days 300 in a year,
power rate Rs 4.50 per kWH
X = 0.1626
RS Savings = 0.1626X16X300X4.5
= 3514 /- RS per year
Extra investment RS 2615/-
Payback period = 9 months

Energy cost for a 15 years usage at Rs 4.50 / kWH is staggering 14.10
lacs as compared to buying cost of Rs 7215/-. Also the energy kWH rate
is likely to only go up in future.
If we compare initial purchase price of the motor with the cost of energy
it uses over it working lifetime, the initial cost represents less than two
percent of its lifetime cost in most of the cases .

So it makes a great deal of sense to choose an eff1 level motor whenever a motor is needed to drive any applications. Combining this with usual Crompton greaves motors reliability, wide service network (over 180 service points all over India), the wise choice is Crompton greaves EFF1 motor.

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Flame Proof Motors

THE WIDEST AVAILABLE RANGE

SQUIRREL CAGE MOTORS
0.37 kw to 355 kw (Frames E80 toE355 LX)
SLIP RING MOTORS
22 kw to 160 kw
(Frames EW 250 M to EW 315 L)

STANDARD SPECIFICATIONS

VOLTAGE : 415 ± 10% Other Voltage class (220 V - 660 V) available on request.	FREQUENCY : 50 ± 5% 25 HZ to 60 HZ available on request.
Combined variation : ± 10 % (absolute sum)	INSULATION : Class F Class 'H' can be given on request.
RATING/DUTY : Continuous (S1) Intermittent duties available on request.	MOUNTING : Horizontal foot mounting (B3) Other mountings available on request.
PAINT : Epoxy anticorrosive painted surface (Standard shade 631 as per IS - 5)	AMBIENT / TEMPERATURE RISE : 45⁰C/75⁰C. Higher Amb. upto 60⁰C on request.
TEMPERATURE CLASS : T4	DEGREE OF PROTECTION : IP 54 - E80 - E132 M E225 M to E355 LX (IP55 with canopy can be offered.) IP55 - Frame E 160L to E 200 L.
ERTL / CCOE (PESO) / DGMS approvals as a standard feature. For BASEEFA approval please contact nearest branch office/works.

APPLICABLE STANDARDS :

Enclosure	IS 2148 EN 50018
Performance	IS325 BS 5000 (Part 10) IEC60034 -1
Performance for Mines	IS 3682
Dimensions Foot	IS 1231 IEC60072-1
Flange	IS2223 BS4999 Part 414

INDUSTRIAL APPLICATIONS :

• Coal Mines. • Petro Chemicals & Chemicals.

• Oil Mines & Rigs. • Fertilizers.

• Solvent extraction plants. • Paints & Varnish Industry.

• LPG Bottling plants. • Agro Chemicals.

• Drugs & Pharmaceuticals. • General Industry.

SPECIAL PURPOSE MOTORS FOR

1. Longwall mining equipment.		2. High pressure mine ventilation fans with plug & socket arrangement.
3. Auxiliary mine ventilation fans with rod mounting / flange mounting.		4. Belt conveyors and armoured face/ chain conveyors.
5. Side dump loaders, load haul dumpers		6. Haulages (squirel cage and slipring motors).
7. Dewatering pumps.		8. Sucker rod pumps.
9. Mud agitators & mud pumps.		10. Slurry extraction pumps.
11. Air compressors & blowers.

SPECIAL DESIGN FEATURES AVAILABLE

1. Dual voltage (550/1100V) with 9 terminal connections as per NCB 625		2. Non standard voltage and frequency variation
3. Dual voltage (1:2 or 1: ratio) Tripple voltage (1: : 2 ratio)		4. Energy efficient motors High slip motors Motors for frequent starts/stops/reversals
5. 10,12,16,18,24,32 pole motors		6. Special performance requirements
7. Class H insulated motors		8. Low vibration and noise level
9. Special Bearings		10. Tacho mounting
11. Special shaft material		12. Canopy
13. Plug & socket arrangement (30 to 300 Amps, 650 & 1100V) for underground equipments.		15. Special RV/RA for slipring motors.
16. Space heaters, thermisters.		17. Multispeed motors.
18. Double /taper/non standard shaft extention		19. Non standard paint shade
20. Motors for use with variable frequency inverter supply

TERMINAL BOX AND TERMINAL ARRANGEMENT

• Cast iron construction, forming a separate flame proof enclosure capable of containing internal explosions		• Standard position on right hand side viewed from driving end side except in frames E 80, E/EW 315 L & E 355 LX where it is on top.
• Terminal box on top on specific request.		• New terminal box with spigotted cover & gland plate/sealing box in frames E 160 to 355 LX with following advantages
• Inherently IP 55.		• Spaciously designed for accommodating bigger cables.
• Double decker terminal arrangement for easy termination of two cables.		• Anti loosening terminal arrangement
• For slipring motors, separate terminal box for stator & rotor terminations provided. Stator terminal box is on left hand side while rotor terminal box is on right hand side, viewed from driving end.		• Conduit plate is provided as standard while sealing box provided for group I gases.
• Separate terminal box for auxiliary terminals (space heaters, thermisters) for frame 225 and above on request.

TERMINAL STUD

• Fully non hygroscopic thermosetting moulded glass filled compound.		• Increased clearances & creepages.
• Anti loosening arrangement.		• Metallic bush insert to take tightening pressure. Eliminates breakage of insulation (E160-315LX frames)

BEARING CHART :

BEARING CHART :		STATUTORY APPROVALS :

FLAMEPROOF MOTORS FOR GROUP IIC ATMOSPHERE
A complete range of Crompton Greaves flameproof squirrel cage motors for gas group IIC is now available for Indian Industries as an import substitute. The motors are manufactured as per the most stringent requirements for IIC atmosphere. The motors are duly tested at ERTL. For more details, please contact our nearest branch office / works.

AVAILABLE Pending for approval.
* STANDARD Temperature class T4. Other classes available on request. * For IIA, IIB Gas Groups

CMRI	:	CENTRAL MINING RESEARCH INSTITUTE, DHANBAD.
DGMS	:	DIRECTORATE GENERAL OF MINES SAFETY, DHANBAD.
CCE	:	CHIEF CONTROLLER OF EXPLOSIVES, NAGPUR.
DGFAS & LI	:	DIRECTORATE GENERAL FACTORY ADVICE SERVICE & LABOUR INSTITUTE, MUMBAI.
BIS	:	BUREAU OF INDIAN STANDARDS, NEW DELHI.
BASEEFA	:	BRITISH APPROVALS SERVICE FOR ELECTRICAL EQUIPMENT IN FLAMMABLE ATMOSPHERES, UK.
ATEX	:	EUROPEAN DIRECTIVE
ERTL	:	ELECTRONIC REGIONAL TEST LABORATORY

NOTE:* Motors as per UK based standards can be supplied against specific enquiries.

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Crane Duty Motors

APPLICATION :

Prabal series squirrel cage/slip ring Crane duty motors are specially designed for service on cranes and hoists. They can also be used for similar applications such as material handling equipments, and cranes of all types. These motors can serve as auxiliary motors in rolling mills or wherever intermittent duty drives are required.
These are duty type rated motors developing high starting torque with low starting current. The motors are suitable for frequent starts/ stops and reversals. Also rapid acceleration is achieved by high pull out torquelrotor inertia ratio.

TYPICAL APPLICATIONS :
Crane duty motors are used for following applications in majority: Cranes & hoists: long travel drive, cross travel drive, main hoist, auxiliary hoist. Material handling equipments: various conveyors Lifts Rolling mills

RANGE :
Manufacturing range for cast iron slip ring crane duty motors is from 112 to 400 frame. The same for squirrel cage motors in cast iron enclosure is from 80-400 & in aluminium enclosure is from 63-160.

MOUNTING :
Squirrel cage crane duty motors are supplied with horizontal foot- mounting. However, motors suitable for foot / flange / face mounting or any combination of these with vertical or horizontal orientation can be offered when required. Slip ring motors are normally available with foot mounting Flange mounting can be supplied on specific request.

POWER SUPPLY : Crane duty motors are suitable for 3 phase supply and can be wound for any single voltage from 220 to 650 volts and frequencies from 50 Hz or 60 Hz. The rotor voltage is committed for stator supply of 415 V, 50 HZ.For other supply conditions, Rv to be confirmed from CG.
AMBIENT TEMPERATURE : The motors are rated at 45°C ambient temperature. For temperatures, other than 45°C, a deration factor has to be applied as indicated below.

Altitude :
The motors are suitable for altitude upto 1000 m above mean sea level. For altitudes more than this, deration factor shall be as per below

STANDARD OPERATING CONDITIONS

Power supply	:	415 volts, 3 phase, 50 Hz
Voltage variation	:	± 10%
Frequency variation	:	± 10% (absolute sum)
Ambient temperature	:	45°C
Altitude	:	upto 1000m.

STANDARD SPECIFICATIONS
PERFORMANCE AND FIXING DIMENSIONS
The motors are manufactured with standard metric frame sizes,
and they comply with the following standards (latest versions).
IS: 325    IS:4722
IS:1231   IS:2223
IS:3177   IEC:60034-1
IS: 807
Motors with following steel plant specifications also can be
supplied on request:
IPSS: 1-03-003 IPSS:1-03-004
For detail dimensions, please refer drawings on page 31-37 in this
publication.

CONSTRUCTIONAL FEATURES: (MECHANICAL)
STATOR FRAME AND ENDSHIELDS

Made of high quality cast iron conforming to IS:210, ribbed externally to ensure maximum heat dissipation. All components are machined on CNC machines ensuring concentricity and correct alignment. The windings and working parts are completely enclosed and air is forced over the stator body by fan, mounted on
the shaft and protected by a cowl. The feet are integrally cast with the body. This ensures sturdiness and resistance to vibrations.

STATOR AND ROTOR CORES

Both the stator and rotor cores consist of low loss and high permeability steel stampings which are assembled under pressure and rigidly secured by end plates.

ENCLOSURE AND COOLING

Standard crane duty motors have IP55 degree of protection as per IS:4691. IP 56 & 66 can be provided on request. The cooling code of motor is IC 411 as per IS:6362.

SHAFTS AND BEARINGS

The shaft is of high grade steel and of appropriate diameter to withstand the bending and torsional stresses. All shafts are ultrasonically tested for any minor flaw in the material. Shafts are machined to extreme fine limits to ensure fit and interchangeability of bearings. The motors are provided with single shaft extension.
Special shafl extensions like:

change in diameter and length,
taper shaft, with threaded end, and with hexagonal nut and lock washer.
double shaft extensions, (cylindrical & taper) are available on request.

Motors are provided with deep groove ball bearings. They are mounted with extreme care in dust proof housing. (Refer bearing size table for details). Sealed bearings are provided for motors upto frame 225M. Grease lubricated bearings are used on frames 250 and above. The correct amount of grease is filled in the bearings during manufacturing. On line greasing facility is provided for 250 frame & above to facilitate greasing of bearings without dismantling the motor.
For provision of insulated bearings, please refer to CG.
PRABAL 'E' SERIES MOTORS

PRABAL SERIES MOTORS:
(Bearing references for single shaft extension)

TERMINAL BOX

Terminal box is provided with IP55 degree of protection. The box can be turned through 3600 in steps of 900 to give cable entry from anyone of four positions. The terminal boxes are suitable for BS screwed conduit. However, fittings like double compression type cable glands are available on request.

Terminal box position can be provided as per table below:

SLiPRING AND BRUSH GEAR
All sliprings are made of cupro-nickel. The slip ring unit is having high insul~tion resistance ensuring minimum wear and breakdown. The brush holders are assembled as a complete unit which can be easily replaced. The slipring enclosure is dustproof & has a cover with accessibility for inspection. The slip rings are epoxy moulded / fabricated type as per requirement.

MOTOR GO. SQ.
For large no. of starts, it is necessary that the accelerating time of the system should be as small as possible. For this purpose, total inertia of the system (motor GO sq. + Load GO sq.) should be minimum. Motor GO sq. value and permissible load GO sq. are indicated in the tables.

INTERCHANGEABILITY AND SPARES
All Prabal series crane duty motors are built to standardised designs and all spare parts are interchangeable.

CONSTRUCTIONAL FEATURES (ELECTRICAL)
Class of Insulation:
Stator: Class F insulation with temperature rise limited to class B
Rotor: Class H insulation with temperature rise limited to class F
Prabal series crane duty motors with higher class for stator insulation (class H) can also be offered on request.

WINDINGS STATOR WINDINGS
Stator winding (and rotor winding in case of slipring motors) consists of enamelled copper wire impregnated with superior quality class F varnish which is rigid at all working temperatures. Stators in motors with frame 280 & above are manufactured with vacuum pressure impregnation process as a standard. All rotors irrespective of frame size are processed with vacuum pressure impregnation. This gives added electrical & mechanical strength to the winding for high number of starts. The varnish has a high insulation resistance and excellent resistance to moisture, saline atmosphere, acidic/ alkaline fumes, and also to oil and grease. The
insulation gives complete reliability under all atmospheric conditions, including humid tropical climates. Stator and rotor wound packs are subjected to surge test before impregnation.

ROTOR WINDINGS
1. Wound rotor
Rotors of slip ring motors are wound and impregnated similar to stator windings. In addition, rotor windings are braced with resiglass banding. This gives protection against centrifugal forces experienced by overhang during overs peed and frequent reversals. Gelcoat is provided on the winding overhang for better
consolidation and protection from vibration. Strip wound rotors are provided on frames 355 and above.

2. Cage rotor
Rotors are of pressure diecast aluminium upto 355 frame. They are designed for high starting torque, suitable for high number of starts. Cooling fins cast integrally with the rotor cage, improve the cooling action within the motor. All rotors (cage and wound) are dynamically balanced to comply with the requirements of IS: 12075

TERMINAL ARRANGEMENT
The terminals are mounted on a moulded base and are enclosed in a box having an inspection cover. In case of slip ring motors, three terminals for stator and three terminals for rotor are terminated in terminal box with adequate creepage and clearance. The rotor terminals are in the same box as those of the stator.
Separate terminal box for rotor terminals is provided for NDW355LX & NDW400LX frames. This simplifies wiring and maintenance.

EARTHING
One earthing terminal is provided in the terminal box and two terminals on mounting feet.

ACCESSORIES:
Crane duty motors can be provided with various accessories as per table below:

Space heating for anti condensation:
Space heaters are used for avoiding accumulation of moisture/water in humid atmospheres. In motors upto 200 frame size, motor windings can be heated up to keep winding temperature above ambient by 5 to 10 degrees, by giving low supply voltage upto 10% of rated voltage. Supply voltage is to be adjusted by keeping 20-25% rated current. Thermal protection: Stator windings can be provided with PTC thermisters for alarm/trip or PT 100 type resistance temperature
detectors according to the accessories table provided. Bearings can be provided with PT100 type resistance temperature detectors as per enclosed table 6.

ROTOR VOLTAGE
The rotor voltage of the motor is kept such that the insulation of the rotor and of the associated switchgear is not unduly stressed during rapid plugging when rotor voltage can rise to 2 to 3 times the rated value. Rotor voltage for slip ring motors is as per performance tables enclosed. Special rotor voltage can be offered for wire wound rotors with confirmation from CG.

PULL OUT TORQUE
The pull out torque value at rated voltage is indicated in the respective tables. Since available torque varies as the square of the supply voltage at motor terminals, an allowance for voltage drop in long cables, live rails and collectors must be considered. These voltage drops are significant when motor is operated at pull out point, since current at this point is much higher than the rated current. Pull out torque is maximum for 300 starts/hour class. This high pullout torque ensures rapid acceleration irrespective of drop in effective torque due to stepped rotor resistance. However, care to be taken that gears and other drive transmission equipments can withstand this peak torque.

OVERLOAD CAPACITY
The motors can withstand 1.5 times the rated current for 2 minutes without suffering damage. This feature makes the motor suitable for severe duties experienced on the crane or similar applications.

LIFE OF THE MOTOR
Crompton Greaves crane duty motors are designed and manufactured with carefully selected and tested insulating materials to ensure long services. The life of the motor mostly depends upon the life of the insulating materials since bearings, brush gears, slip rings etc. can be replaced easily during normal maintenance.

MAXIMUM PERMISSIBLE OPERATING SPEED
All 4, 6, 8, and 10 pole motors are designed for withstanding an over speed of 2.5 times rated synchronous speed or 2000 rpm whichever is less.

VFD CRANE DUTY MOTORS ( Cast Iron)
Crane duty squirrel cage motors when used with inverter drives give better current control, speed control & improved operation. Current control is similar or better than slip ring motors & maintenance cost /efforts are less than equivalent slip ring motors. Current control of VFD driven motors is better than standard squirrel cage motors.
Prabal series Inverter duty motors are provided with special insulation system suitable to withstand voltage spikes when fed from inverters. The motors are provided with following features:
• Vacuum pressure impregnation of stator winding, this gives less voids & stronger winding.
• Strengthened insulation system for withstanding voltage stresses.

Standard features:
Base Voltage: 220 volts to 650 volts Base frequency: 50 or 60 Hz Insulation class: Class "F' or 'H' as required (temp rise limited to class B)
CG make motors are suitable for the following IGBT drive output
• High frequency in the range of 3kHZ - 6 kHZ. Voltage rise time> 0.1 sec.
• Voltage spikes up to 1600V and rise time of 0.1 sec.
• Voltage spikes up to 1600V and rise time of 0.1 sec.
• THD < 3%
Mode of operation: Modes of operation of inverter driven motors are classified according to type of load & speed range. They are:
• Variable torque
• Constant torque
• Constant power.

In case of cranes/hoists, the mode of operation is constant torque. The typical speed range is from 10% to 100% of synchronous speed. The speed during lowering cranes in unloaded conditions may be more. The limiting speed should not exceed 2.5 times of rated synchronous speed or 2000 rpm whichever is less.
The selection of frame size for various duty type & starts shall be as per table enclosed.
For higher cable length from drive to motor, use suitable dv/dt filters & a lower switching frequency.
Use of insulated bearing at non driving is recommended for frame size above 315 to reduce bearing failure due to shaft currents.
Use of thermisters for frames upto 250 & resistance temperature detectors for frame 280 & above is recommended.

Additional losses & temperature rise:
Harmonics of voltage & current in a cage induction motor supplied from a converter cause additional iron & winding losses in the stator & the rotor.
There is no simple method to calculate the additional losses & no general statement can be made about their value.
When the motor is tested with converter supply at rated load, base voltage & base frequency, the permissible temperature rise will be within the limits of the insulation system used. For example when a motor havinf class F insulation system is tested with sinusoidal supply at rated voltage , rated frequency & rated load, may have temperature rise within class B limits. However, when the same motor is tested with converter supply under same test conditions, the temperature rise will be within class F limits. It is assumed that, while testing with converter supply, the HVF factor of converter output supply, is maximum 3%.
Hence the outputs of crane duty inverter driven motors are as listed in the table on page 28-30.

GENERAL REQUIREMENT:
All additional general requirements like accessories, paint shade, insulation class, degree of protection, voltage and frequency variation shall be available at extra cost. The cost structure of extra features is same as that for standard motors.

DEFINITIONS
The terms used frequently in intermittent duly drive and hoisting are as bellow:
1. Duty:
Operation of the motor at load including no load and de- energised period to which the motor is subjected, including the sequence and duration.

2. Cyclic duration factor (CDF) :
The ratio between the period of loading including starting and electric braking and the duration of the duty- cycle expressed as percentage.

3. Starting:
The process of energizing a motor to bring it upto rated speed from rest.

4. Jogging or inching:
This is an incomplete start during which the motor does not attain more than 25% of the rated speed.

5. Electric braking:
A system in which a braking action is applied to an electric motor by causing it to act as a generator.

6. D.C. Injection braking:
A form of braking of an induction motor in which a separate dc supply is used to magnetise the motor.

7. Plug braking:
A form of electric braking of an induction motor obtained by reversing the phase sequence of its any two lines.

8. Regenerative braking:
A system of electric braking in which energy is returned to the supply system.

INTERMITIENT DUTY TYPE RATINGS.

The basis of the ratings is that of thermal capability, taking into account,
i) Frequency of starting (starting class).
ii) Percentage of time during each operating cycle the motor is energized, (CDF)
iii) The number and type of cycle per hour, (duty class)
iv) and the inertia of the motor and the load.

CLASSIFICATION OF STARTING:
The starting classification for a motor indicates the maximum permissible number of starts per specified inertia, taking into account complete starting, jogging or inching and electric braking. Rating for the commonly used starting, i.e. 6,150 and 300 starts/hour class, are listed in this publication. However, following factors can be used to calculate output rating for different number of starts and CDFs.

Squirrel cage motors:
4 jogs or inchings or jerks = 1 start
1 plug braking = 3 starts
1 dc injection braking = 2 starts
1 plug reversal = 4 starts

Slip ring motors:
4 jogs or inchings or jerks = 1 start
1 plug bra~ng = 0.8 starts
1 plug reversal = 1.8 starts

DUTY TYPE :
Crane duty applications can be classified into duty types S2 to S10. The duty types are as per table 4 below:

The duty types S2 to S5 are explained in detail as per below:

Short time duty (duty type S2) :
Operation at constant load during a given time, less than that required to reach thermal equilibrium, followed by a rest and de- energised period of sufficient duration to re-establish machine temperatures within 2°C of the coolant. (See figure 1) The recommended values for the short time duty are 10, 30 and 90 minutes.

Intermittent periodic duty (duty type S3) :
A sequence of identical duty cycle, each including a period of operation at constant load and a rest and de-energised period. These periods being too short to attain thermal equilibrium during one duty cycle. (See Fig. 2) In this duty type, the starting current dose not significantly affect the temperature rise. Unless otherwise specified, the duration of the duty cycle is 10 inutes. The recommended values for the CDF are 15, 25, 40 and 60 percent.

Intermittent periodic duty with starting (duty type S4) :
A sequence of identical duty cycles, each cycle including a significant period of starting, a period of operation at constant load and a rest and de-energised period. These periods being too short to attain thermal equilibrium during one duty cycle. (See Figure 3) In this duty, the stopping of the motor is obtained either by natural deceleration after disconnection of the supply or by means of braking such as mechanical brake which does not cause additional heating of the windings.

Intermittent periodic duty with starting and braking (duty type S5)
A sequence of identical duty cycles, each cycle consisting of a period of starting, a period of operation at constant load, a period of rapid electric braking and rest and de-energised period. The operating cihd rest and de-energised periods being too short, to attain thermal equilibrium during one duty cycle. (See Fig. 4) Note : In all above types of duties, the loading period and rest period of the cycle are so short that the steady state temperature is not reached. While working on these identical cycles continuously, the motor temperature rise must not exceed the permissible values for a given class of insulation.

Selection of motors for hoist motions:
For hoisting motor, the power required shall not be less than that computed from the following:

Where, derating factor will be taken as 12%,
Kw = one hour power rating for dc motors & power rating at (8 - 40%) cyclic duration factor for ac motors.
M = mass of rated load on hook plus weight of hook block & wire ropes in tones
V = specified hoisting speed in M/min
E = combined efficiency of gears & sheaves
   = (0.93)n x (0.98)m for sleeve bearings
   = (0.95)n x (0.99)m for antifriction bearings
   = (0.985)n x (0.99)m for hardened profile ground & oil splashed lubricator, where
n = number of pairs of gears
m = total number rotating sheaves passed over by each part of the moving rope attached to the drum
Cv = service factor for vertical motion depending on type of motors,
    = 0.67 for ac motors,
    = 0.5 for dc motors
Cdf = duty factor
Camb = Derating factor for ambient temperature as per table 1.

For an ac hoist motor, the specified full load hoist speed must be obtained at not more than rated torque, therefore, the calculated full load kw must be multiplied by :

Where sufficient information is not available values given in table 9 below for duty cycles, cyclic duration factor & starting class corresponding to mechanism class shall be used. The values given are based on the following formula:

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DC Motors

INTRODUCTION

Crompton Greaves Ltd, a name synonymous with rotating machines have DC Motors Technology inherited from SIEMENS, Germany, the pioneer and world leader in DC Motors. Today, Crompton Greaves offers an entire range of world class DC Motors.

The motors are manufactured at Crompton Greaves Ltd. Ahmednagar factory, an ISO accredited set up having state - of - the - art manufacturing facilities. The high quality standards maintained in manufacturing and testing give superior electrical and mechanical features - making the motors most suitable for operating in tropical environments.

The Ahmednagar factory - manufacturing DC Motors

SPECIAL FEATURES		APPLICATIONS
Fully laminated yoke construction offering excellent commutation - suitable for 6 pulse thyristor power supply		Plastic Extruders
Skewed Rotor construction - ensuring low noise		Printing Machines
Vacuum pressure impregnation for armature winding - ensuring high insulation strength		Steel Rolling Mills and Wire Rod Mills
High dynamic response		Sugar Industry
Compact, low weight and highly energy efficient		Textile Mills
Larger size of bearings - for longer life and trouble free operations		Apron Feeders
Constant / uniform pressure brush holders		Machine Tools
Easy fitting and retro-fitting of filters		Rubber Industry
		Cement Mills
		Cable Industry
		Paper Mills
		Material Handling

Laminated Yoke DC Motor manufactured at Ahmednagar		Aux Mill Duty DC Motors as per IPSS/AISE Standards are also manufactured

SPECIFICATIONS :Laminated Yoke

Laminated Yoke Construction Range :
Output Frames	: 2.5 kW to
550 kW	: ASBG 100 to ASBG 315

BRUSH LIFETIME :

BRUSH MATERIAL, COMMUTATION :
Practically sparkless commutation with converter feeding, even under overload conditions is achieved. As a result, the brushes have an extremely long life.

FORCED COOLING DETAILS

		The blowers of DC Motors have three phase motors with wide range of winding and supply voltages. The blower motors are selected strictly in accordance with the air quantity required and ensures cool running of motors under the specified operating loads / overloads. The terminal box of blower motors are easily assessible.

NOISE LEVEL

		The noise levels of the motors have been calculated in accordance with DIN EN 21 680 and are well below the values permitted by EN 60034 - 9. They have been achieved both by means of design measures and by optimising the magnetic circuit and the separately driven fans. * At No Load, with blower ON, with thyristor supply

TECHNICAL DATA

AUX MILL DUTY D.C. MOTORS TO AISE/IPSS STANDARDS
Crompton Greaves Ltd., a name synonymous with rotating machines backed by its long proven expertise in the field of DC motors offers the entire range of state of art Auxiliary Mill Duty 800 series DC motors in frames 802 to 818 from 7.5 kW at 900 RPM to 187 kW at 435 RPM to AISE/IPSS Standards.

These motors are very rugged, reliable and suitable for steel mills or like applications.

818, 816, 814, 812, 810, 808, 806, 804, 803 & 802 frames are manufactured at CGL, LT Motors Division, Ahmednagar (Lam yoke DC motor frames 100 to 280 are also manufactured here). M3 Division is accredited with by BVQI for ISO 9001 Certification Quality Management System.

SALIENT FEATURES
• Conforming to AISE technical report no. 1-1991 / IPSS 1-03- 002-94.		• Replaceable shaft.
Full speed, half speed and quarter speed designs available.		• Double shaft extension 1:9.6 taper with key way paralle to taper as per AISE or 1:10 taper with key way parallel to shaft axis as per IPSS.
• Suitable for operations upto 500 volts.		• Convertible between TENV & TEFV enclosure or with top mounted blower unit.
• Suitable for operation on 3 phase, 6 pulse thyristor converter.		• Loose hanging leads or terminal box as required.
• Class 'H' insulation with class 'F' temperature rise limits.		• Axial play of 3 mm approximately of shaft.
• Armature class 'H' with VPI in solventless polyesterimide resin.		• Brush position of 45 deg. for easy access for maintenance (except in case of laminated yoke version).
• TIG welding of armature coil connection to commutator.		Motor mounting dimension can be matched to replace 600 series motors to AISE or Russian standard.
• Split / Non split yoke without compensating winding or non split laminated yoke with compensating winding. However split yoke is preferred for 808 & above frames and compensating type for 812 & above frames.

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AC Generators

AC Generators
	Crompton Greaves AC Generators are state-of-the-art, self-excited, self-regulated and dependable source of power. A modern integrated manufacturing facility for rotating machines, ISO 9001 certified by BVQI UK, with structured TQM and 6 SIGMA implementation and SAP/R3 enabled, also houses dedicated plant for AC Generators deploying superior techniques and processes in each specialized field of design, material specifications and procurement, CNC machining, assembly, testing & packing.... with stringent quality standards predominating throughout. These generators incorporate advanced European Technology and are designed for optimum performance using high-end software solutions. With well-qualified engineers and technocrats, backed by a strong R & D Team, Crompton Greaves have fully harnessed long experience in design and software to offer a range of innovative, reliable and efficient AC Generators.

SPECIFICATIONS AND OPTIONAL FEATURES :

FORCED COOLING DETAILS

SPECIAL FEATURES

RANGE

APPLICATIONS


• Ease of maintenance with integrated components and outboard Exciter/Rotating Rectifier.
• A reliable long life with superior class 'H' insulation.
• Higher motor starting capability.
• Compact, light and sturdy die cast aluminum stator for frames upto 250, offer superior finish.
• Specially designed compact slipring and brush assembly.
• High thyristor load withstand capability for Cell-Phone and Telecom applications.
• Short circuit withstand capability.
• Wide range of coupling discs / adaptor for single bearing construction suitable for wide range of Engine makers.

Brushless AC Generators :
• 5 kVA to 625 kVA, in 3 phase, 415 V, 50 Hz, 0.8 pf (lag) Single or double bearing.
• 5 kVA to 40 kVA in single phase, 230 V, 50 Hz, 0.8 pf (lag) Single & double bearing

Slip-Ring AC Generators :
• 5 kVA to 82.5 kVA, in 3 phase, 415 V, 50 Hz, 0.8 pf (lag) Single or double bearing.
• 5 kVA to 20 kVA in single phase, 230 V, 50 Hz, 0.8 pf (lag) Single & double bearing
• 2 Pole Alternators (both Slipring and Brushless) are available on request.


• Industries
• Telecom, Cell-Phone Towers
• Defense
• Agriculture
• Marine
• Hotels, Hospitals, Commercial & Residential Complexes, Petrol pumps
• Construction sites, Stone Crushers & hot Mixing plants.
• Trailer mounted mobile sets for rental markets

OPERATING IN DIFFERENT ENVIRONMENTS
• For use of the AC Generator at altitudes higher than 1000 m. above the sea level, it is necessary to derate by a factor of 4% for every 500 m above 1000 m
• If the ambient temperature exceeds 40 deg. C, the derating factor to be incorporated is 4% for every 5 deg. C of increase.

STANDARDS COMPLIANCE
• IEC : 34
• BS : 5000 (Part 99)
• EN : 50081
• IS : 4722 & 13364 (Part I & II) with CE mark for brushless designs.

MECHANICAL FEATURES
• Aluminium frame die - cast stator upto 250 and steel stator for higher frames.
• Sturdy cast iron endshields fixed on to the stator frame by high tensile screws.
• High quality steel shafts are amply designed to take care of overload and short circuit stressed conditions.
• Sturdy, dynamically balanced rotors are designed for withstanding the runaway engine speed and are with continuous damper cage for high performance under arduous conditions of parallel operations.
• Aluminum fans for effective cooling extends the winding life.
• Screens or louvered covers on all openings for safety.
• Easy mount SAE adaptors are offered with single bearing AC Generators to simplify coupling with popular engines.

AUTOMATIC VOLTAGE REGULATOR (AVR)
Model	Frame
SR 7/3 SR 7/6 UVR 7 SR 7/5	132 & 160 Frame 200 & 250 Frame 250L & Above For Slipring (on request)

• Under Speed Protection with LED indicator.
• Over Excitation Protection with LED indicator
• 2 Phase sensing with Senseloss LED Indicator
• Designed for Thyristor load without additional filter circuits.
• Moulded construction for protection against shocks, vibrations and adverse atmospheric conditions.
• Parallel operation facility for SR 7/6 and UVR 7.

UNDER SPEED PROTECTION (with AVR)
•Protects both the AC Generator and V/f sensitive loads. The AVR has provision for setting the frequency below which voltage dropping occurs linear to speed. This feature also enables the prime mover to recover the speed faster during motor starting

WINDING AND INSULATION SYSTEM
•The armature coils of the stator main winding are made from dual coated, class 'H' copper wires, Single/Double Layer concentric fractional pitched winding offers simplicity, reduced overhangs, neat look while reducing voltage distortion and superior capability to cope with non-linear loads. The auxiliary winding in stator provides power to the AVR, improving the motor starting capability of the AC Generator. The insulation system is class 'H'. All wound components are impregnated in an unsaturated polyester resin of 200 class temperature. The impregnation provides much needed rigidity and protection against the harsh environment, typical for the AC Generators applications

RADIO INTERFERENCE
The AC Generators are having negligible Radio Frequency Interference and meets in general the limits permitted by VDE 0875 (N)

WAVE FORMS
A.C. Generators are designed to give an excellent output wave-form. The total harmonic content of line-to-line voltage wave-form on no load is less than 5% as per the limits specified by IEC/IS Standards.

OVERLOADS
A.C. Generators are capable of delivering an overload of 10% for one hour after every six hours of running. an overload of 10% for one hour after every six hours of running.

MOTOR STARTING DUTY
Each kVA of AC Generator is capable of starting 1 HP of Induction Motor with use of auxiliary winding except for Submersible Pump & Lift Duty applications. (Upto 200 frame slipring type only)

VIBRATION AND NOISE
CNC machining with close tolerances and repeat Accuracy for uniform air - gap and rotor dynamic balancing for low vibrations ensure efficient, smooth and silent performance.

TERMINATION

• Integral Terminal Box is provided for higher reliability.
• Top Terminal Box with side cable entry ensures wiring flexibility.
• Spacious terminal box accommodates all types, including aluminum cables

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