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

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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