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ABB AMXE160 Manual

Motors for heavy electrical vehicles
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MANUAL
Motors for heavy electrical vehicles
AMXE160

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Summary of Contents for ABB AMXE160

  • Page 1 — MANUAL Motors for heavy electrical vehicles AMXE160...
  • Page 2 In no event shall ABB be liable for direct, indirect, special, 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.

  • Page 3: Table Of Contents

    — Table of contents Introduction ..............................5 1.1. General ..............................5 1.2. Intended application .........................6 1.3. Warranty ..............................6 1.4. Information on electromagnetic compatibility ................6 1.5. Required qualifications for personnel who handle the motor ..........6 1.6. Safety ..............................7 1.7. Contraindications ..........................7 Product description ............................8 2.1.
  • Page 4 MOTORS FOR HEAVY ELECTRICAL VEHICLES Waste disposal and Recycling ........................29 9.1. General ...............................29 9.2. Dismantling the traction motor ....................29 9.2.1. Normal carbon steel .......................29 9.2.2. Electrical silicon steel non oriented ................29 9.2.3. Stainless steel ........................30 9.2.4. Cast iron ...........................30 9.2.5. Aluminium ........................30 9.2.6.

  • Page 5: Introduction

    ABB or authorized by the end user. • Actions shown in this manual are only to be performed by trained personnel authorized by ABB or The actual appearance of the motor may vary from the illustrations in this manual, depending on Actions shown in this manual are only to be performed by trained personnel authorized by •...

  • Page 6: Intended Application

    MOTORS FOR HEAVY ELECTRICAL VEHICLES 1.2. Intended application The motor is primarily intended to be used for heavy electrical vehicle applications, as a traction motor, generator or auxiliary motor. It also fits as propulsion or auxiliary unit in Marine segment. Due to the nature of their electrical and mechanical operating conditions, improper installation or operation, as well as insufficient maintenance, could introduce hazards which could lead to severe bodily injuries or damages to property.

  • Page 7: Safety

    The motor is not designed, sold or intended for any use except as indicated above. Furthermore, it is not intended to be used outside of the motor specifications or limitations. The motor must be in good working order. If technical modifications are considered, they shall always be approved by ABB and be carried out by qualified personnel.

  • Page 8: Product Description

    MOTORS FOR HEAVY ELECTRICAL VEHICLES 2. Product description The motor is an AC four (4) pole motor of synchronous type. The motor features a tailored design, optimized for high energy efficiency and a competitive performance/weight ratio. The motor is actively cooled by a separate liquid cooling system which is connected to its integrated cooling pipe via inlet and outlet connectors placed on the frame.
  • Page 9 ProduCT dEsCrIPTIon Item no. Designation External shaft seal End shield DE Stator frame Rating plate Separate rating plate with liquid cooling system data End shield NDE Connection box DE bearing Shaft NDE bearing Figure 1. Exploded view of the motor.

  • Page 10: Technical Data

    MOTORS FOR HEAVY ELECTRICAL VEHICLES 2.1. Technical data The exact type designation and identification data are shown on the rating plate located on the motor, see Figure 1. An example of a rating plate can be seen in Figure 2. Figure 2.

  • Page 11: Expected Lifetime

    The warning and shut down limits are only valid for short term operation. Prolonged needs to be evaluated based on the duty cycle. Please contact your local ABB sales office for operation at high stator winding temperatures will significantly impact the bearing grease technical support.

  • Page 12: Transportation And Storage

    MOTORS FOR HEAVY ELECTRICAL VEHICLES 3. Transportation and Storage 3.1. Transportation 3.1.1. Delivery to customer The motor is transported fastened to a pallet. Leave the motor on the pallet until it is time to place it in its working place, i.e., chassis. During short term storage, place the motor so that it is out of the way of any other goods being handled, and on a flat, vibration-free surface.

  • Page 13: Lifting Of Motor

    TrAnsPorTATIon And sTorAgE 3.1.3. Lifting of motor Warning - Heavy Components Risk of personal injury when lifting the motor. The weight of the motor is visible on the rating plate. Only skilled and trained personnel should carry out dismantling. NOTE: Check that the lifting eye bolts are undamaged before lifting.
  • Page 14 MOTORS FOR HEAVY ELECTRICAL VEHICLES The angle between the lifting chains shall be a maximum of 60°, see Figure 6. Figure 6. Lifting of motor.

  • Page 15: Storage

    10 MΩ (measured with 500 V DC and corrected to 25°C). If the reference resistance value is not attained, the stator winding is too damp and must be oven dried. Please contact your local ABB sales office for technical support. NOTE: To avoid risk of electric shock, the motor frame must be grounded and the windings should be discharged against the frame immediately after each measurement.

  • Page 16: Motor Installation In Vehicle

    MOTORS FOR HEAVY ELECTRICAL VEHICLES 4. Motor installation in vehicle 4.1. Mechanical installation 4.1.1. Preparation and lifting Remove the anti-corrosion coating. Always use the holes for the lifting eye bolts when lifting the motor, see Figure 5 and Figure 6. 4.1.2.

  • Page 17: Installation Of Motor In Vehicle

    MoTor InsTAllATIon In vEhIClE NOTE: Lubricate the splines with a suitable molybdenum disulfide grease. 4.1.3. Installation of motor in vehicle For dimensions involving the motor’s flange and side support, see the outline drawing. The product code is visible on the rating plate, see Figure 2. For side support mounting, see Figure 1.

  • Page 18: Liquid Cooling System Installation

    MOTORS FOR HEAVY ELECTRICAL VEHICLES 4.2. Liquid cooling system installation Remove the protective covers from the cooling inlet and outlet threads (internal G 1/2") and install the mating cooling connectors, see Figure 9. To prevent leakage, it is advisable to use a mating cooling connector equipped with an O-ring seal and apply thread sealant (Loctite 577 or similar) in the internal thread.

  • Page 19: Electrical Installation

    The motor needs an inverter to operate. The inverter must be able to supply 3 phase AC current and be capable of controlling the motor. The motor has been tested and optimized together with the ABB Abbreviations and nomenclature used in this manual: HES880 inverter.
  • Page 20 MOTORS FOR HEAVY ELECTRICAL VEHICLES Figure 11. Connection box at delivery and 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: Operation

    When connected to the wheels, voltage can be generated which can be harmful to the motor and other components in the system, this is valid even if the motor is suspected to be damaged or failed. If the temperature sensors are not functional, please contact ABB before proceeding.

  • Page 22: Inspection And Maintenance

    MOTORS FOR HEAVY ELECTRICAL VEHICLES 6. Inspection and maintenance Carefully planned and carried out service and maintenance of the motor helps to maintain high reliability of the motor and avoid consequential damages. The use of recommended parts and tools is essential to warrant the correct servicing of the motor. Special tools, devices, liquids and lubricating media are necessary.

  • Page 23: Inspection And Maintenance Intervals

    InsPECTIon And MAInTEnAnCE 6.2. Inspection and Maintenance intervals NOTE: The need for maintenance can vary depending on local conditions. It is important to follow the recommendations to ensure a fully working motor. Action Interval Chapter Visual inspection Weekly 6.3.1 Detailed visual inspection 1500 h in operation or every 6 months* 6.3.2 Bearings...

  • Page 24: Bearings

    The bearings, see Figure 1, are lifetime lubricated and require no maintenance. However, listen for any abnormal noise or increased vibration from the bearings and contact your local ABB sales office if such exist. The expected lifetime of the grease inside the bearing is dependent on the motor´s duty cycle and external loads.

  • Page 25: Re-Painting

    InsPECTIon And MAInTEnAnCE Warning – High pressure cleaning May introduce a risk of particles entering the eyes or skin. Use protective glasses and gloves. Follow the instructions from the manufacturer. Warning – Dangerous liquid May cause serious damage to the lungs if consumed. Dries out the skin.

  • Page 26: Spare Parts And Consumables

    MOTORS FOR HEAVY ELECTRICAL VEHICLES 7. Spare parts and consumables Spare parts must meet the requirements defined by ABB. The warranty is only valid if recommended spare parts are used. 7.1. List of spare parts and consumables Spare parts and consumables must be stored in a vibration-free, dry, moisture and dirt-free storage. The parts must be stored in a heated room where the temperature variations are small.

  • Page 27: Trouble Shooting

    D-end or DE: Drive side of motor. • and eliminated immediately, whereby prompt action can often avoid serious damage. In case of phenomena which cannot be satisfactorily explained, please contact your local ABB sales office for ND-end or NDE: Non drive side of motor. •...
  • Page 28 Smoke appears from the motor. Fire after flash-over or short circuit Disconnect the motor, remove it. Rewinding is in a part of the stator winding. most likely necessary, please contact ABB for further instructions. Motor current is abnormally high. Demagnetized rotor magnets.
  • Page 29 WAsTE dIsPosAl And rECyClIng 9. Waste disposal and Recycling 9.1. General This instruction concerns the disposal and recycling of low power traction motors. The traction motors are designed in such a way that it is easy to separate different components and types of material from each other, making it easier to recycle.
  • Page 30 MOTORS FOR HEAVY ELECTRICAL VEHICLES 9.2.3. Stainless steel • Name plate • Rotor end plates (support plates) • Connection flange (331) 9.2.4. Cast iron • DE-shield (12) 9.2.5. Aluminium • Stator frame (11) • NDE-shield (13) 9.2.6. Copper Copper is mostly integrated 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.
  • Page 31 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 MOTORS FOR HEAVY ELECTRICAL VEHICLES Appendix 1 Installation check list Installation date Motor serial number General Has the manual been read and understood? □ Has the motor been stored according to what is described in the manual? □ Are suitable and correct personal safety equipment available? □...
  • Page 33 InTroduCTIon...
  • Page 34 — For more information and contact details: www.abb.com/motors&generators...

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