03 / 2013

EMZ high-voltage motors & drive systems

→ Product series of EMZ high-voltage motors
→ Resistant starters and electrical soft starters
→ Medium-voltage frequency converters
Preface
Dipl.-Ing. Benedikt Mathiaszyk
Managing Director Large Drive & Projects
EMZ‘s premises in Recklinghausen
cover 20,000 m2, whereby 5,000 m2
alone are for warehousing, a further
1,800 m2 for workshops and 800 m2
used for office space.
2
Dear Ladies and Gentlemen,
We are pleased to present our product series of high-
voltage motors and large drives to you with this catalogue.
EMZ stand for products and services of excellent quality,
quick delivery and competitive prices. With the use of mod-
ern manufacturing processes and high quality materials,
we guarantee maximum reliability and operational safety.
Thanks to our years of experience, we are familiar with
the comprehensive requirements of internationally-
operative OEMs and know the practical needs of the
operators in the plants.
Our qualified sales team take your individual require-
ments into account and provide personal, expert advice
to help you choose the right high-voltage drives and
complete drive-systems.
Ask us; we will be delighted to assist you with your
enquiries and look forward to working with you.
Applications & Guidelines

Applications Made by EMZ

We are represented worldwide in all branches, e.g.
cement, chemicals, paper, steel and plant engineering.
With our qualified personnel we guarantee optimal and
individual support during every phase of the project.
Reliability and service are the highest priority at EMZ.
See for yourself!
To offer you a top-quality drive-system concept, the
right choice of manufacturing facilities is crucial. The
high quality standards of our products are guaranteed
by the certification of our production sites in accord-
ance with EN ISO 9001 standards.

Norms and Standards

EMZ high-voltage motors and drive-systems are On request, the EMZ motors can be manufactured
manufactured according to current IEC and EN 60034 in accordance with NEMA MG2 standards and IEEE
standards and comply with the following regulations: testing regulations.

Design & performance DIN/EN 60034-1

Protection type DIN/EN 60034-5
Cooling DIN/EN 60034-6
Construction type DIN/EN 60034-7
Noise emission DIN/EN 60034-9
Vibration levels DIN/EN 60034-14
Electrical insulation DIN/EN 60085
Soft starters DIN/EN 60947-4-2
Frequency converters DIN/EN 61800

EMZ High-voltage motors 3

Our Product Range
01
Compact Series
AKR squirrel-cage motors
ASR slipring motors
→ Cooling type IC411
→ Rib-cooled squirrel-cage
motors and slipring motors
4
02
Modular Series
AKD/L/W squirrel-cage rotors
ASD/L/W slipring motors
→ Cooling types IC01/611/W81
→ Modular squirrel-cage motors
and slipring motors
03
Special Designs
Taylor-made individual construction
→ 100 % interchangeable replicas
→ Special designs for individual
drive application
→ Development of appropriate
drive concepts
→ Cooling types IC
01/31/411/511/611/W81
→ Customised designs
04
Soft Starters & Resistance Starters
Soft starters for squirrel-cage
motors
Liquid and oil cooled resistance
starters for slipring motors
05
Frequency Converters
Low-voltage 690 V up to 2,500 kW
Medium voltage
2,200 V to 11,000 V for engine
performance of max. 30 MW
06
Synchronous machines
SD/L/W synchronous machines
→ Cooling types IC 01/611/W81
→ Modular synchronous motors
and generators
EMZ High-voltage motors 5
Our Resources for High-Voltage Motors

01 02 03
Design and Calculation Construction High-Voltage Windings

→ 3D construction tools Compact series AKR/ASR → Corded two-layer winding design

→ Optimised stator housing
design
→ Torsion analysis of shafts
→ Magnetic calculation of
active parts
→ Low-noise fan design
→ Optimised efficiency
→ Compact cast-iron frame
→ dual-circuit cooling system
with internal and external fan
→ Low-vibration bearing end shield
construction
→ Optimised performance and
maximum power in a
compact design
→ Voltages 3,000 V to max. 15,000 V
→ High-voltage windings in thermal
classes F and H
→ Thermal load in thermal class
B (80K)
→ Advanced VPI technology
→ Robust design of the coil-winding
heads with great mechanical stability

Modular series AKL/ASL

→ Modular basic concept
→ Different types of protection
and cooling feasible
→ Torsion-resistant welded
steel housing
→ Direct derivation of the
torque to the base construction
→ Realisation of the mechanical
dimensions according to the
customer’s specifications

6
04
Rotor windings
Squirrel-cage rotors
→ Squirrel-cage motors with
robust copper windings for
tough start-up conditions
→ Reduced heat-transfer
resistances
→ Grooved and hard-soldered
bar/ring connections
→ Standard applications with
aluminium winding
Slipring rotors
→ VPI insulation
→ Insulation system in
thermal classes F and H
→ Great mechanical stability
05
Bearings
→ High-quality SKF and FAG
ball/roller bearings
→ Fixed bearings of standard
design on the DE-side
→ Reinforced bearings (DE)
for belt drive application
→ Special construction for
higher axial loads
→ High-quality Renk sleeve
bearings with oil-ring lubrication
→ Special designs for
sleeve bearings with
hydrostatic device
06
Testing
→ All measurements according to
IEC/EN 60034-1 regulations
→ All motors undergo complete
routine testing
→ Type testing including
thermal measuring on request
→ Special testing:
→ Tan Delta measuring
→ Impulse-voltage testing
according to IEC/EN 60034-15
→ Polarisation index
→ Vibration analyses
→ Single-coil testing
EMZ High-voltage motors 7
Surface-cooled three-phase squirrel-cage motors
AKR series
The rib-cooled squirrel-cage motors of our AKR series
are manufactured with a cast-iron housing as standard.
A compact design and great reliability characterise our
motors.
Thanks to the optimised dimensioning of the stator,
rotors and fan, losses are reduced and optimum
efficiency values achieved.
AKR engines are surface cooled according to IC411
(IEC 60034-6) and transfer the heat losses via the
ribbed motor housing and the bearing end shield to the
external cooling air.
8
The innovative dual-circuit cooling system, with its
unidirectional internal fan, ensures a consistent tem-
perature distribution inside the motor. This increases
the service life and the reliability of the machine.
Our motors are available in the IEC frame sizes 315,
355, 400, 450, 500 and 560 mm and can be manufac-
tured with a maximum output of 1,800 kW.
AKR motors are suitable for heavy and extreme condi-
tions. They are available in standard design for opera-
tion with fixed speed but also for speed-regulated use
with frequency converters.
 01 | Compact Series

550 kW squirrel-cage motor AKR 355-04 as a drive for a vacuum Final assembly 800 kW squirrel-cage motor AKR 450-04.
blower for a paper factory.

Design Power range

→ Manufactured according to the current → Performance 150 to 1,800 kW
DIN, IEC and EN standards → Voltage 2,000 to 11,000 V
→ Compact cast-iron housing → Frequency 50 and 60 Hz
→ High output related to frame size → Number of poles 2 to 12-pole
→ Two-circuit cooling system for → Protection type IP 55
internal and external cooling → Cooling type IC 411
→ Reliable bearing design with SKF/FAG → Mounting IM B3 and IM V1
rolling bearings
→ Fixed bearing on the DE-side Applications
→ VPI insulation system in thermal class F → Pumps
→ Use of copper rotors for difficult → Compressors
start-up conditions → Ventilators
→ Designed for use with fixed speed and → Chippers/Refiner
for VFD application → Conveyor drives
→ Mills

EMZ High-voltage motors 9

Modular three-phase squirrel-cage motors
AK series
Based on the basic module of a welded stator housing,
the squirrel-cage motors of the AK series can be adapted
perfectly to suit the individual requirements of each
application.
The high-quality design and manufacture guarantee
the reliability of EMZ motors.
The following types are available
(type designation according to IEC 60034-5/6):
AKD series
Protection type IP23/W24/R54
cooling type IC01/31
AKL series
Protection type IP55 | cooling type IC611/616
AKW series
Protection type IP55 | cooling type IC81W
10
Thanks to the use of roller bearings by the manufac-
turers SKF and FAG, we guarantee extended operation
interval and low maintenance costs.
All motors can be supplied on request with oil ring
lubricated sleeve bearings manufactured by Renk.
Depending on the bearing loads, the sleeve bearings are
self-cooled or externally-cooled with an oil lubrication
unit.
The rotor windings of the basic design are made of rec-
tangle copper bars which are hard-soldered with the
grooved short circuit rings. For special applications with
difficult start-up and operating conditions, we use dou-
ble-cage rotors. For high speed applications, the end
rings are secured with additional antimagnetic stain-
less steel retainer rings.
 02 | Modular Series

1,200 kW fan drives for AKL 560-06 for a cement plant. 2,500 kW refiner drive AKL 710-06 for the paper industry.

Power range Applications

→ Performance 150 to 15,000 kW → Pumps
→ Voltage 2,000 to 13,800 V → Compressors
→ Frequency 50 and 60 Hz → Ventilators
→ Number of poles 2 to 24 pole → Chippers/Refiner
→ Protection type IP 23/W24/R54/55 → Shredders
→ Cooling type IC 01/31/611/81W → Conveyor drives
→ Mounting IM B3 and IM V1/V10 → Mills/crushers

EMZ High-voltage motors 11

Modular three-phase slipring motors
AS series
Slipring motors are used when a high starting torque
and/or a low starting current is/are required. These
motors offer maximum availability and are used espe-
cially in applications with high external moment of iner-
tia, such as mills and big fans or where the main power
supply is weak.
Identical to the modular cage-rotor series, the slipring
motors of the AS series are development onto the basic
module of the welded stator-housing construction.
12
Modular housing design
The base of AS slipring rotors is a compact and
modular housing construction. The welded stator hous-
ing is ribbed on the inside and designed to be very sta-
ble and torsion-resistant. The torque loads and peak
loads that occur during operation are diverted directly
to the base construction and the foundations.
With modular cooling elements, all the necessary
protection and cooling types can be realised.

Spider shaft of a 4,000 kW slipring rotor during assembly.
Rotor design
Depending on the size of the motors, a cylindrical or
a welded spider shaft is used for the rotor. By using
massive shafts, all slipring rotors can be constructed
with a second shaft end designed for twice the nominal
torque. The rotor winding is executed in thermal class F
and manufactured as a corded two-layer winding. The
individual rotor bars are hard-soldered after insertion
and secured with a sturdy bandage against the occur-
ring centrifugal forces.
Bearings
By using high-quality rolling bearings manufactured
by SKF and FAG and sleeve bearings manufactured
by Renk, we can guarantee a long service life and low
maintenance costs.
02 | Modular Series
4,000 kW ball-mill drive ASL 710-06 in a cement mill.
The following designs are available
(descriptions according to IEC 60034-5/6):
ASD series
Protection type IP23/W24/R54 | cooling type IC01/31
ASL series
Protection type IP55 | cooling type IC611/616
ASW series
Protection type IP55 | cooling type IC81W
Quality
The entire manufacturing process, from design to exe-
cution, manufacture to final testing, is integrated into the
quality assurance system according to EN ISO 9001.
EMZ High-voltage motors 13
Modular three-phase slipring rotor

Slip rings & carbon brushes

The standard version slipring motors are available with
permanently-mounted carbon brushes or, on request,
with a short-circuit and brush-lifting device. In both cas-
es, the slipring body is mounted on the NDE-side. For
the execution with the permanently-mounted carbon
brushes, the slipring compartment is designed with a
separate cooling circuit that is seperated from the sta-
tor winding and equipped with filter pads for the carbon-
brush dust.
The standard version corrosion-resistant sliprings are
manufactured from a chrome-steel alloy (Remanit).
Special metal-graphite alloys are used for the carbon
brushes, depending on load capacity.
Service
The use of high-quality carbon brushes and brush hold-
ers, as well as the load-optimised design of the carbon
brushes, are essential criteria for low wear-and-tear
parameters.
With our qualified staff, we offer an all-round service
for the operation and continuous monitoring of the slip-
ring system during operation within the facility, thus
ensuring that our customers benefit from a high level
of operational safety and reliability.

14
 02 | Modular Series

1,950 kW slipring rotor ASL 560-06 for a coal-mill drive in a steel works. 3,500 kW slipring rotor ASL 710-06, 11,000 V, 50 Hz drive for a
cement ball mill.

Power range Accessories

→ Performance 150 to 15,000 kW All EMZ high-voltage motors can be equipped with a
→ Voltage 2,000 to 13,800 V wide range of accessories:
→ Frequency 50 and 60 Hz
→ Number of poles 4 to 24 pole → Pt100 resistance thermometers for winding
→ Protection type IP 23/W24/R54/55 and bearing
→ Cooling type IC 01/31/611/81W → SPM detectors
→ Mounting IM B3 and IM V1/V10 → Bentley Nevada vibration monitoring
→ Anticondensation heating elements
Applications → Contact thermometer
→ Ball/roller mills → Vibration monitoring 4–20 mA
→ Crushers → Star point terminal box
→ Rolling mills → Current transformers for differential protection
→ Shredders → Tachometer generators
→ Ventilators → Water-leakage monitoring
→ Refiners → Slip-ring compartment lighting
→ Conveyor drives → Pressure switch for filter monitoring

EMZ High-voltage motors 15

EMZ Engineering
Customised solutions
Thanks to our years of project experience, we can offer
you comprehensive technical advice and assistance for
your drive solutions. From development to construction,
manufacture to operation, we guarantee a standard of
quality for our products and service that will convince
you of our expertise.
→ 100 % identical replicas for existing drives
→ Special designs for specific drive applications
→ High efficiency owing to the use of
loss-optimised materials
→ Project management including installation,
commissioning and training
16
100 % interchangeable replicas for existing motors
Based on our experience and the numerous successfully-
completed projects, we guarantee an all-round service
when you require replaceable spare motors.
→ Accurate recording of the actual state of the
application in your facility
→ Comparison with current requirements
→ Development of a suitable concept
→ Detailed co-ordination of construction and
accessories
→ Routine and type testing according to
IEC/EN 60034-1
→ Installation, commissioning and training

Slide bearings with hydrostatic port.
Hydrostatics
To ensure the adequate lubrication and safe operation
of sleeve-bearing motors, the rotor must rotate in the
bearing shell with a minimum speed that is based on
the bearing size and the revolution. If the minimum ro-
tation speed for specific applications falls below what
is required, the oil film can tear and destroy the sleeve
bearing.
By using a rotation-speed independent hydrostatic unit,
the rotor shaft in the bearing shell is lifted with a pres-
sure of 80 to 150 bar, thus ensuring a safe and wear-
and-tear-free operation at very low rotational speeds
and when starting up.
The hydrostatic units can be connected independently
from a central oil lubrication unit directly to the oil
reservoir of the sleeve bearing.
03 | Special Designs
8,350 kW slipring motor ASL 1120-08 for a sinter fan in a steel plant.
Special applications
→ Stator windings with executed star point for
Star-Delta starting
→ Constructions for reduced starting currents
→ Double-cage designs for increased starting
torque and heavy start-up conditions
→ Noise-reduced designs with air inlet and
outlet muffler
→ Reinforced housing and bearing designs for use
with shredders with a maximum vibration
level of 28 mm/s
EMZ High-voltage motors 17
Starter for three-phase high-voltage motors
Resistance starters
Three-phase resistance starters are connected to
the rotor circuit of the motor to start asynchronous
machines with slipring rotors. According to the slip-
dependent reduction of the starting resistance and de-
pending on the counter torque, the motor will acceler-
ate with a defined starting torque.
Liquid starters with short-circuit contactor
and circulation pump.
18
Liquid starters
The liquid starter is a continuously-adjustable resistor
with a three-phase electrode system which is moved in
an electrolyte. Through the concentration of the electro-
lyte, the starter resistance can be changed and the start-
er optimally adjusted to the respective load conditions.
Oil-cooled drum starters
The oil-cooled drum starter consists of individual cast
iron resistance elements which are manufactured ac-
cording to the required resistance parameters and
mounted in an oil reservoir.
 04 | Soft Starters & Resistance Starters

Medium-voltage soft starters

1,500 kW; 6,000 Volt soft starter. Start-up 6,000 V soft starter.

Soft starters
Our electronic soft starters allow a controlled reduc- Technical Data
tion of the starting current and the start-up torque → Vacuum contactor
when starting cage rotors. → Vacuum bypass contactor
→ Control voltage: 110 V - 220 V AC, 110 V DC
Power range → Motor-protection relay (MSR)
→ Performance max. 16,000 kW → Current and voltage transformers
→ Nominal voltage 1,500 to 15,000 V → Multifunction display (DMA)
→ Nominal current 60 to 2,000 A → Soft start and soft stop
→ Current limiting
→ Pump control programmes
→ Adjustable torque and current characteristics
→ Dual setting
→ Boost start (high starting torque)

EMZ High-voltage motors 19

Medium-voltage frequency converters
Used with permission of Rockwell Automation, Inc.
Applications
Medium-voltage frequency converters are used in ap-
plications where powerful speed control is required
and where low-voltage frequency converters have
reached their economic and technological limits. With
these, the rotation speed and the torque of asynchro-
nous and synchronous machines are optimally adapted
to suit the actual requirements; energy consumption is
optimised and the CO² emissions reduced.
Medium-voltage frequency converters are used in
many areas:
→ Energy industry
→ Water-resources industry
→ Open-cast mining
→ Oil and gas industry
→ Metal industry
→ Building materials’ industry
20
Advantages
By using medium-voltage frequency converters the
copper content in the connecting leads can be reduced
by up to 80%, in comparison to a low-voltage solution.
The space requirement for the supply lines, the instal-
lation costs and the power dissipation of the connect-
ing cables used and, ultimately, the cooling costs, will
reduce – while efficiency increases.
Thanks to substantial energy savings, medium-voltage
frequency converters have very short payback periods.
We provide ready-to-use solutions for voltage ranges
from 2.2 kV to 11 kV with an power of approximately
250 kW to a maximum of 30 MW.
 05 | Frequency Converters

Frequency converter 1.2 MW Multilevel frequency converter 2,000 kW; 6,600 Volt.

Technical designs Even if a power unit fails, the frequency converter can
You do not need to do without the usual frequency-con- still operate – but with a reduced output current and re-
verter intelligence. Different applications and designs duced efficiency.
are possible:
Depending on the feed and intermediate-circuit technol-
→ A synchronised bypass of a start-up converter ogy used, international standards such as UL, CSA, IEEE,
for consecutive hauling-up of various motors GOST are maintained.
→ The design with air and water cooling
→ Multilevel technology
→ Operation in weak field areas We use applications for:
→ Operation of standard high-voltage motors in
combination with “Direct to Drive” technology → Pumps
→ Compressors
→ Extruders
→ Mixers
→ Fans
→ Mills

EMZ High-voltage motors 21

Three-phase synchronous machines

SG series
Synchronous machines of the SG series are especially Power range
economical because of low maintenance costs, opera- → Performance 250 to 35,000 kVA
tional safety and high efficiency. → Voltage 2,000 to 13,800 V
→ Frequency 50 and 60 Hz
Our wide range of synchronous generators is fitted with → Number of poles 4 to 40 pole
a brushless, electronically-controlled DC excitation as → Protection type IP 23/R54/55
standard. The electronic voltage control ensures opti- → Cooling type IIC 01/31/611/81W
mum voltage accuracy and an excellent dynamic op- → Design IM B3 and IM V1/V10
erating behaviour. A design with static exciter and slip-
rings is available on request.

Depending on your requirements, we manufacture syn- Applications

chronous machines for indoor and outdoor installation → Industrial power plants
with mounted air/air or air/water heat exchangers. → Hydropower plants
→ Test field applications
→ Compressor drives
→ Pump drives

22
 06 | Synchronous machines

EMZ catalogues

Would you be interested in further EMZ catalogues? Other EMZ catalogues:

If you are, please visit our website at www.emz.de. → EMZ Reference Catalogue
All catalogues and references are available to download → EMZ Image Brochure
in our “Download” section or as a printed edition. → EMZ Low-Voltage Motors’ Catalogue
→ EMZ High-Voltage Motors’ Catalogue

Catalogue request
eMail: marketing@emz.de

→ Let us convince you of our expertise;

take a look at our reference catalogue!

EMZ High-voltage motors 23

Contact: EMZ Product Portfolio:

EMZ Elektro-Maschinen-Zentrale GmbH Electric motors (for high and low voltage)
Richardstrasse 70 → Three-phase squirrel cage motors up to 15,000 kW
45661 Recklinghausen, Germany → Three-phase slipring induction motors up to 15,000 kW
→ DC motors up to 2,500 kW
Phone: +49 2361 -6909 -0
Fax: +49 2361 -6909 -99
Gear motors
→ Helical-gear motors
Web www.emz.de
→ Worm-gear motors
eMail info@emz.de
→ Bevel-gear motors

Transformers (for high and low voltage)

→ Oil-filled transformers up to 20,000 kVA
→ Cast-resin transformers up to 6,000 kVA
→ Dry-filled transformers up to 1,000 kVA

Power electronics
→ Frequency converters
→ Inverters

EMZ product configurator

→ Configure your products to suit your
individual requirements
NEW
→ View current stock availability
www.emz.de
→ Detailed technical information,
dimension tables1and photos of every product
→ Review your order, including delivery status