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  • CGIE/AMoto

    rs f

    or

    Genera

    l A

    pplicati

    on IE2 Motor Series

  • Introduction

    Global warming is a reality and world over people are working towards reduction in carbon foot print.

    Electric motor applications, in Indian industry, consume about seventy percent of the generated electrical energy. Improving

    efficiency of the motor is therefore a major concern in energy-efficiency efforts.

    Electric motors with improved efficiency, in combination with frequency converters can save about 7% of the total worldwide

    electrical energy. Roughly one quarter to one third of these savings come from the improved efficiency of the motor.

    A need was felt amongst users, consultants and manufacturers in India to revise existing BIS standard IS 12615:2004 to harmonize

    with the international standards. This will lead us to be in line with international code of standards and practices. This will also

    result in having uniform test procedures to facilitate the end user to compare the performance and energy efficiency of motors.

    Motors from 0.37kW to 375kW make up the vast majority (approximately 90%) of installed motor population and are covered

    by the standard IS 12615:2011. This fulfills the need of the manufacturers to design motor for a global market. This standard

    defines four efficiency classes for nominal frequency 50Hz.

    Salient features of BIS standard IS 12615:2011 (second revision)

    This standard is primarily based on IEC 60034-30:2008 issued by the International Electrotechnical Commission except that

    additional performance parameters other than efficiency values have also been included.

    The efficiency levels in IS 12615:2011 are based on test methods specified in IS 15999 (Part 2/sec 1):2011 / IEC 60034-2-1:2007.

    The standard specifies methods used to determine losses and efficiency, with the objective to calculate efficiency values

    more accurately.

    New IE efficiency classes are as given below

    Efficiency Class Description

    IE1 Standard efficiency Comparable to eff2

    IE2

    IE3

    IE4

    High efficiency Comparable to eff1

    Premium Premium

    Super premium Super premium

    As per the standard, efficiency class of IE4 is under consideration and would be incorporated later. The standard IS 12615:2011

    covers low voltage, AC three phase squirrel cage, single speed induction motors for

    Rated voltage

  • Energy efficient cage-induction motors are typically built with more active material to achieve higher efficiency and hence

    the starting performance of these motors differ somewhat from motors with a lower efficiency. The locked rotor current

    increases approximately by 10 to 15 percent for increase in each level of efficiency for the same output power. For replacing

    existing motors, this should be checked by the user with manufacturer for proper sizing of the protective devices.

    Old efficiency levels were Eff2 and Eff1 (as per CEMEP). For calculation of these efficiencies, fixed stray load losses (0.5%

    of motor output) were assumed. Now IS 12615:2011 refers to IS 15999 (Part 2/sec 1):2011 / IEC 60034-2-1:2007 for calculation

    of efficiency. This calculation is based on the new methods of stray load loss measurement specified in the standard.

    The effect is in the reduction of efficiency as compared to the earlier values.

    Energy Efficient Induction Motors

    (Three phase squirrel cage induction motors)

    Bharat Bijlee has introduced a complete range of IE2 High

    efficiency motors

    Product Range

    Type Frame Size kW range

    2H - IE2 High efficiency 71 TO 355L 0.37 TO 355*

    Standards

    All motors comply with following Indian & International

    standards

    National/International Standards

    IS : 325 Three Phase Induction motors

    specifications.

    IS/IEC 60034-1 Rotating electric machines: Part 1

    Rating and Performance

    IS : 900 Code of practice for installation &

    maintenance of induction motors.

    IS : 1231 Dimensions of foot mounted A.C

    Induction motors

    IS : 2223 Dimensions of Flange mounted

    A.C Induction motors

    IS 15999 part 2 Rotating Electrical Machines -

    section 1 Standard Methods for determining

    /IEC 60034-2-1 losses and efficiency from tests

    IS /IEC 60034-5 Degree of protection provided by

    the integral design of Rotating

    Electrical Machines (IP code) :

    classification

    IS : 6362 / Designation of methods of cooling

    IEC 60034-6 for Rotating Electrical Machines

    IS : 12065 / Permissible Limits of noise level

    IEC 60034-14 for Rotating Electrical Machines

    IS : 12075 Mechanical Vibration of Rotating

    Electrical Machines

    IS : 12615:2011 Energy Efficient Induction Motors

    Three phase Squirrel Cage.

    IEC 60072 Dimension & Output rating of

    Rotating Electrical machines.

    CE MARK

    All motors have CE mark on the nameplate

    ELECTRICAL FEATURES

    Standard Operating condition

    Supply Conditions (Voltage & Frequency)

    Voltage : 415 V 10%Frequncy : 50Hz 5%Combined variation : 10%

    Ambient o

    Motors are designed for ambient temperature of 50 C

    Altitude

    Motors are designed for an altitude up to 1000m above mean

    sea level.

    Re-rating factors

    The re-rating applicable under different conditions of supply

    voltage, frequency, ambient & altitude are obtained by

    multiplying following factors.

    Variation in supply Voltage & Frequency

    10 5 10 100

    12.5 5 12.5 95

    15 5 15 90

    Voltage

    Variation %

    Frequency

    Variation %

    Combined

    Voltage &

    Frequency

    Variation %

    Permissible

    output as %

    of rated

    value

    *Note : Motors above 355kW & up to 1250kW are

    available in frame size 355, 400 & 450 with double

    ventilated cooling system. Please contact our Sales.

  • Variation in Ambient Temperature & Altitude

    Method of starting

    Our motors are suitable for following method of starting

    kW rating Method of starting No. of leads

    Upto & including 1.5 kW DOL 6

    415V - Star

    240V - Delta

    Above 1.5 kW DOL or Star / Delta 6

    All Bharat Bijlee motors are suitable for inverter duty

    application. (Refer page 5)

    Starting Time and Duty Cycle

    Motors are designed for continuous (S1) Duty. Other type of

    duty (S2 to S9) can be offered on request. The motors can safely

    withstand 3 consecutive starts from cold condition &

    2 consecutive starts from hot conditions. In applications where

    more severe starting conditions are encountered,

    a special enquiry should be made e.g.

    Drives with high inertia e.g flywheel drives, eccentric

    presses, large fans etc.

    Drives involving intermittent duty of motors with

    frequent starts e.g. rolling mills, centrifuges and

    conveyor motors, etc.

    The enquiry should be accompanied with following

    information.

    2

    GD and relevant speed of driven equipment

    Duty cycle/sequence of operation/no. starts/hours

    Speed-Torque diagram of driven equipment

    Method of braking (Electrical or Mechanical)

    Insulation and Endurance

    The Motors are provided with class F insulation scheme with

    temperature rise limited to class B. These motors can be used 0

    either at ambient temperature of 55 C or overloaded

    continuously by 10% (service factor = 1.1). The temperature

    rise will be still within limits of class F.

    The slot insulation consists of Nomex-polyster-Nomex (NPN).

    All insulation materials used are adequately resistant to the

    action of microbes and fungi.

    Winding & Insulation for Inverter Duty Motors

    The stators are wound with polysteremide coated

    with polyamide-imide top coat, (dual coated)

    wires as per IS 13730 : part 13, grade -II thermal class 200

    copper wires.

    Vacuum Pressure Impregnation (VPI) is provided

    to windings.

    Depending on the voltage wave rise time (dv/dt) and the

    maximum peak to peak voltage at the motor terminals,

    suitable insulation schemes are provided.

    On customer's demand, insulated bearings are offered from

    frame size 132 and onwards on the NDE side of the motor.

    Options

    Motors with class 'H' insulation can be offered on request.

    Thermal Protection (For Winding & Bearing)

    PTC Thermisters / thermostats. RTD etc. can be embedded in

    stator winding on request. In case of frame sizes 250M &

    above Bearing Temperature Detectors (BTD) can be supplied

    on request.

    Earthing Terminals

    Two earthing terminals are provided on the body and one

    terminal is provided in the terminal box.

    Anti-condensation Method

    In order to avoid condensation of water inside the motors,

    they can be heated up by connecting a voltage 4 to 10% of

    rated voltage to the motor terminals. Adequate heating is

    obtained with current equal to 20-25% of rated motor current.

    Alternatively any of the methods indicated in IS : 900 for

    heating stator winding could be adopted.

    Motors can also be offered with built in space heaters in

    frame size 90 and above.

    MECHANICAL FEATURES

    Enclosures: ( Material & Terminal box location)

    Motors are offered with following enclosure

    Frame Size Enclosure

    Materials Standards Option Available

    63-80 Aluminum TOP ----

    90S-112M Aluminum TOP ----

    Cast Iron RHS TOP & LHS

    132S & 132M Aluminum TOP -

    132S-225M Cast Iron RHS TOP & LHS

    250M-355L Cast Iron TOP RHS & LHS

    Terminals Box Location

    Degree Protection

    All motors have IP55 degree of protection as per IS/IEC 60034-

    5. Higher degree of protection such as IP56, IP66 can be

    provided on request. All flanged motors are additionally

    provided with oil tight shaft protection on driving end side.

    Table 2

    Cooling Type Cooling Code

    TEFC IC 411 Standard

    TENV IC 410 On Demand

    FORCED COOLED IC 416 On Demand

    All foot mounted motors are with integral feet construction.

    All motors up to 280 frame are with integral bearing covers

    and motors in frame 315 and above are with separate

    bearing covers.

    Cooling

    All motors are totally enclosed Fan Cooled (TEFC) The cooling is

    effected by self driven, bi-directional centrifugal fan protected

    by fan cover. The Type of cooling is as per IS 6362 / IEC 60034-6.

    Forced cooing arrangement can be provided for frame 132S

    and above.

    Altitude Permissible

    above output as %

    sea level m of rated value

    1000 100

    1500 97

    2000 94

    2500 90

    3000 86

    3500 82

    4000 77

    PermissibleAmb.

    output as %Temp. C

    of rated value

  • Bearing & Terminals Box Details

    Note: L10 bearing life is 50,000 hours for directly coupled loads

    through flexible couplings only

    Roller Bearing and Insulated Bearing

    Alternatively motors with insulated bearing on NDE side can be

    offered from frame size 132S & above on request at extra price.

    Motors can also be offered with cylindrical roller bearing (NU)

    on DE side for frame sizes 132S and above at extra price.

    Grease

    Sealed for life bearing (2Z) are filled with grease Unirex N3-of

    ESSO. Others are filled with LGMT3 of SKF make. Special high

    temperature grease can be provided on request.

    On line Re-Greasing

    On line re-greasing arrangement is provided in frame sizes 225S

    and above. For frame size 180M, 180L and 200L it can be

    provided on request.

    Rotor

    Entire range of motors is fitted with dynamically balanced

    aluminum pressure die cast squirrel cage rotors.

    Shaft

    All motors are provided with single shaft extension in

    accordance with IS : 1231. The Shaft material is C40 (EN8) Steel.

    However any special shaft extension and / or special shaft

    material e.g. EN24 or stainless steel grades are also provided

    on request.

    Balancing & Vibration

    Rotors are dynamically balanced with a half key in the shaft

    extension. Vibration grade is 'reduced grade' conforming to IS:

    12075. Other grades as per IS 12075 or IEC 60034-14 can be

    provided on request.

    Noise Level

    Motors are designed for noise level well below the limits

    specified in IS: 12065

    Paint

    All motors are painted with acrylic paint in Blue colour, RAL

    shade No. 5000. Motors used in corrosive atmosphere are

    painted with Epoxy base paint. Any other shade or material

    (e.g. polyurethane paint) can be offered on request.

    Packing

    Motors up to 132M frame are packed in thermacol / corrugated

    boxes. Wooden packing boxes are provided for higher frame

    size. Export worthy packing is also available on request.

    Frame Size

    Bearing nos. C3 Clearance

    Terminals

    Box Type /

    Location

    Terminals No. &

    size of

    cable

    entries

    Max.

    Cond.

    Cross

    Sec.

    area

    mm

    DE NDE No.

    Size

    63 6201 2Z 6201 2Z

    gk030/

    Top

    6

    M4

    13/4

    4

    71 6202 2Z 6202 2Z

    80 6004 2Z 6004 2Z

    90S,90L 6205 2Z 6205 2Z gk130/Top

    6 6

    100L 6206 2Z 6205 2Z gk230/

    Top

    6

    21

    10

    112M 6206 2Z 6205 2Z

    132S,132M 6208 2Z 6208 2Z gk330/Top

    gk330/RHS

    6 M5

    160M,160L 6309 2Z 6209 2Z 16

    180M,180L 6310 2Z 6210 2ZgK430/

    RHS

    6 M6

    2

    1-1/2

    50

    200L 6312

    6212 TB

    225/RHS

    6

    M8

    2 2

    70

    225S, 225 6313

    6213

    250M 6315

    6215TB280/

    Top

    6M10

    150280

    S/M

    2P 6316

    6316

    4, 6

    & 8P6317 6316

    315 S/M

    6319 6319TB315/

    Top6

    M12

    2 2

    240

    315L2

    2 1/2

    355L 6322 6322 TB355/Top 6 M16 2 3 300

    6319 6319

  • Bharat Bijlee IE2 motors suitable to run with VFDs

    Bharat Bijlee offers the entire range of motors suitable to run

    with VFDs.

    Motors are suitable for :

    Constant torque application like crane, hoist, reciprocating

    compressor etc.

    Variable torque application like centrifugal pump, fan,

    blowers etc.

    Constant power application like metal cutting lathes, wire

    winding machines etc. and are custom built to suit

    customer's requirements.

    Motors for constant torque application suitable for speed range

    of 1:10, 1:5, 1:2 etc can be provided. Depending on the speed

    range, motors can be offered with forced cooling

    (IC416) or in higher frame sizes 132S and above. Please

    check with our sales office, for motors to be operated above

    1.5 times the synchronous speed.

    PWM, IGBT devices operate at very high frequencies (2 kHz to

    15 kHz) and have very short rises times leading to high dv/dt.

    Longer cable lengths also contribute to higher voltages

    at the motors terminals due to standing wave phenomenon.

    These stress the insulation of the motors. Bharat Bijlee motors

    are provided with special impregnation system /vacuum

    pressure impregnation and dual coated winding wire to take

    care of these stresses. This insulation conforms to the

    requirements given in IEC 60034-18-41. For voltage higher than

    500 V, refer to our sales office.

    All the motors are provided with six terminals in the terminal

    box. Shaft induced voltage occurs due to the use of VFD. This

    causes flow of currents through bearing which can lead to

    premature bearing failure. Insulated bearings can be provided

    in frames from 132S onwards on request.

    In closed loop system operations, speed feedback is obtained

    through encoder mounted on the shaft of the motors. We

    provide encoder mounting arrangements on Non Drive End

    side shaft of the motors on request.

    For further details and technical offer, please refer to our Sales

    office in your area.

  • Payback Calculations:

    Effect of additional stray load losses for efficiency determination as per IS 12615-2011

    The new standard follows IS 15999 / IEC 60034-2-1 for arriving at the stray load losses. These losses can vary from 2.5%

    in small motors to 0.5% in higher ratings up to 1MW. The earlier standard IS 12615-2004 used for eff1 motors assumed stray

    losses as 0.5% of output. Hence the efficiency values tested by the earlier standard would be 0.5% to 1.5% higher than

    the new standard for the same motor.

    Example is as given below

    Rating 4 Pole

    11kW

    55kW

    Eff1 specified in

    IS 12615-2004 (%)

    91.0

    94.2

    IE2 specified in

    IS 12615-2011 (%)

    89.8

    93.5

    Reduction in efficiency from eff1

    Due to additional stray losses (%)

    1.2

    0.7

    When comparing eff1 motor & IE2 motor, it is necessary to note the difference in testing methods. The standard has

    reduced the efficiency value to take care of this. At first glance a customer would feel that an IE2 motor is inferior to an

    Eff1 motor though both might be identical.

    Hence for any comparison, it is necessary to use the same method of loss calculation. The worked out example shown below

    gives the energy savings per year (for 8000 hours running) of a Bharat Bijlee IE2 motor (normalized for 0.5% stray loss) over a Bharat

    Bijlee standard IS 325 motor

    Rating

    kW

    BBL IS325

    Catalogue

    (eff%)

    IE2

    Catalogue

    (eff%)

    Input Power

    ( kW)

    Additional

    Stray losses

    (kW)

    Nomalized IE2

    Eff with 0.5% Stray

    losses assumed

    IS 325 losses

    (kW)

    IE2 losses

    (kW)

    Saving

    (kW)

    Saving in

    kW/Year

    @8000 Hrs

    running

    11

    55

    89.0

    93.8

    89.8

    93.5

    12.249

    58.824

    0.187(0.2424-

    0.0550)

    0.684 (0.959-

    0.275)

    91.2

    94.6

    1.360

    3.636

    1.062

    3.140

    0.298

    0.496

    2380

    3968

  • Ta

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    Eff

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    Ca

    talo

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    e

    (Eff

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    0.3

    77

    17

    2.2

    73

    .81

    57

    71

    70

    .1

    0.5

    57

    47

    4.8

    76

    .41

    88

    74

    75

    .1

    0.7

    57

    77

    7.4

    79

    .02

    01

    77

    79

    .6

    1.1

    79

    79

    .68

    1.2

    30

    37

    88

    1.4

    1.5

    80

    .68

    1.3

    82

    .94

    12

    80

    82

    .8

    2.2

    82

    .58

    3.2

    84

    .85

    70

    82

    84

    .3

    3.7

    85

    85

    .58

    7.0

    80

    58

    58

    6.3

    5.5

    86

    87

    88

    .51

    42

    68

    68

    7.7

    7.5

    87

    88

    .18

    9.5

    19

    44

    87

    88

    .7

    9.3

    88

    88

    .89

    0.2

    20

    56

    88

    89

    .3

    11

    89

    89

    .49

    0.8

    19

    27

    89

    89

    .8

    15

    89

    .59

    0.3

    91

    .63

    10

    19

    0.2

    90

    .6

    18

    .59

    0.5

    90

    .99

    2.2

    29

    89

    91

    .29

    1.2

    22

    91

    .59

    1.3

    92

    .62

    19

    09

    1.8

    91

    .6

    30

    92

    .69

    29

    3.2

    16

    55

    92

    92

    .3

    37

    93

    92

    .59

    3.7

    22

    43

    93

    92

    .7

    45

    93

    .59

    2.9

    94

    .02

    14

    39

    3.2

    93

    .1

    55

    93

    .39

    3.2

    94

    .34

    92

    39

    3.8

    93

    .5

    75

    94

    93

    .89

    4.8

    55

    49

    94

    .29

    4

    90

    94

    94

    .19

    5.1

    87

    56

    94

    .79

    4.2

    2 P

    ole

    4 P

    ole

    No

    rma

    lize

    d

    IE2

    Eff

    wit

    h

    0.5

    % S

    tra

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    losse

    s

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    vin

    g i

    n

    kW

    h/Y

    ea

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    @8

    00

    0 H

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    run

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    g

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    L I

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    Ca

    talo

    gu

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    (Eff

    %)

    IE2

    Ca

    talo

    gu

    e

    (Eff

    %)

    No

    rma

    lize

    d

    IE2

    Eff

    wit

    h

    0.5

    % S

    tra

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    losse

    s

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    g in

    kW

    h/Y

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    00

    0 H

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    71

    .63

    76

    86

    97

    0.0

    12

    2

    76

    .72

    12

    69

    72

    .97

    4.0

    42

    9

    81

    .34

    13

    73

    75

    .97

    7.1

    43

    4

    83

    .16

    95

    76

    78

    .17

    9.8

    55

    0

    84

    .57

    97

    77

    79

    .88

    1.4

    85

    0

    85

    .99

    84

    80

    81

    .88

    3.4

    89

    5

    87

    .91

    13

    78

    58

    4.3

    85

    .83

    34

    89

    .21

    84

    08

    58

    68

    7.5

    14

    62

    90

    .22

    41

    78

    88

    7.2

    88

    .64

    73

    90

    .72

    53

    88

    88

    88

    9.4

    13

    07

    91

    .22

    38

    08

    8.5

    88

    .79

    0.1

    17

    26

    91

    .92

    52

    09

    08

    9.7

    91

    .01

    48

    9

    92

    .52

    28

    99

    19

    0.4

    91

    .71

    20

    6

    92

    .92

    21

    59

    1.2

    90

    .99

    2.1

    19

    89

    93

    .54

    22

    89

    1.8

    91

    .79

    2.9

    30

    80

    93

    .92

    96

    99

    2.5

    92

    .29

    3.4

    29

    40

    94

    .24

    25

    69

    3.5

    92

    .79

    3.8

    13

    20

    94

    .63

    96

    89

    3.5

    93

    .19

    4.2

    34

    23

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    eff

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    IE2

    Note

    :

    All p

    erf

    orm

    ance v

    alu

    es a

    re s

    ubje

    ct

    to t

    ole

    rance a

    s p

    er

    IS/I

    EC

    60

    03

    4-1

    Effic

    iency m

    easure

    ments

    are

    without

    seals

    .

  • Special Design Features Offered

    Electrical

    Non standard Voltage 42 TO 700V

    Non standard Frequency 50/ 60 Hz with efficiency

    class as per IEC 60034-30

    Motor for wide variation*

    Voltage variation >10%

    Frequency Variation >5%

    Motors with higher

    ambient temperatures

    >50 C

    Polarities higher than 8

    pole

    10pole, 12pole etc

    Dual Voltage motors In ratio 1:v3. 1:2

    Multi Speed motors 2 / 3 speeds

    Class H Insulation Scheme

    Motors with Thermal

    protection

    PTC Thermisters,

    Thermostat, RTD, BTD etc.

    Space heaters 90 Frame onwards

    Motors with starting

    current Limitations

    e.g.

  • NOTES

  • NOTES

  • ED

    1012

    Continuous process of product development/updation entitles us to change the specification in this booklet without prior notice. For latest information, please contact our Sales Office

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    Flat No 1 Sai Sankalp Ground Floor Sankalp Hsg Soc Ltd

    Plot no 14 Cts No 380 Opp Jog Hospital Pand Road Kothrud

    Pune - 411 038 T: +91 20 2432 1267 /2432 4831/2432 0232

    F: +91 20 2433 9210

    Email: [email protected]

    PUNE

    SCO No.333-34 1st Floor Sector 35B Chandigarh.160 022

    T: +91 172 2600532/35 F: +91 172 2600531

    Email: [email protected]

    CHANDIGARH

    202 Arth Complex 8-Rashmi Society Behind A K Patel

    House Mithakali Six Roads Ahmedabad 380 009

    T:+91 79 2642 4187/2642 2455 F: +91 79 2656 3581

    Email: [email protected]

    AHMEDABAD

    Plot No v-71 Neelam Appartment Narendra Nagar Nagpur

    440 015 Mobile-09665093639

    Email: [email protected]

    NAGPUR

    207 1ST Floor Business Plaza Near Ganapa Plaza B-8

    Molal Avenue Jaipur 302 001 T: +91 141 237 2842

    Email: [email protected]

    MUMBAI

    JAIPUR

    M-78 Trade Centre 18 South Tukoganj Indore 452 001

    T: +91 731 2524474/2514486 F: +91 731 2527 505

    Email: [email protected]

    INDORE

    Flat No.8 Mansarawer 2nd Floor 3B Camac Street

    Kolkata 700 016

    T: +91 33 2217 2382/83 F: +91 33 2217 2467

    Email: [email protected]

    EASTKOLKATA

    Electric Mansion 6th Floor Appasaheb Marathe Marg

    Prabhadevi Mumbai 400 025

    T: +91 22 2430 6237/6375 F: +91 22 2437 0624

    REGISTERED OFFICE

    DELHI