ABB AMXE132 User manual

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MANUAL
Motors for heavy electrical vehicles
AMXE132

MOTORS FOR HEAVY ELECTRICAL VEHICLES
2
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NOTICE
The information in this document is subject to change without further
notice and should not be used as a commitment by ABB. ABB
assumes no responsibility for any errors that may appear in this
document.
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.
This document and parts thereof must not be reproduced or copied
for use for other than that of the AMXE132 without ABB’s written
permission. The contents thereof must not be imparted to a third
party nor be used for any unauthorized purpose.
©Copyright 2021 ABB. All rights reserved.

3
1. 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
2. Product description .......................................................................................................................................8
2.1. Technical data .................................................................................................................................. 10
2.2. Expected lifetime..............................................................................................................................11
3. Transportation and Storage....................................................................................................................... 12
3.1. Transportation................................................................................................................................. 12
3.1.1. Delivery to customer ..................................................................................................... 12
3.1.2. Inspection of delivery..................................................................................................... 12
3.1.3. Lifting of motor .............................................................................................................. 13
3.2. Storage ............................................................................................................................................. 15
3.3. Removal of Tectyl before commissioning................................................................................... 15
3.4. Insulation resistance check ........................................................................................................... 15
4. Motor installation in vehicle........................................................................................................................ 16
4.1. Mechanical installation................................................................................................................... 16
4.1.1. Preparation and lifting................................................................................................... 16
4.1.2. Installation of coupling.................................................................................................. 16
4.1.3. Installation of motor in vehicle .....................................................................................17
4.2. Liquid cooling system installation............................................................................................... 18
4.3. Electrical installation ...................................................................................................................... 19
4.3.1. High voltage connection ............................................................................................... 19
4.3.2. Low voltage connection ................................................................................................ 21
5. Operation........................................................................................................................................................22
5.1. Failure mode operation.................................................................................................................. 22
6. Inspection and maintenance ......................................................................................................................23
6.1. Safety Instructions.......................................................................................................................... 23
6.2. Inspection and Maintenance intervals ........................................................................................24
6.3. Inspections and maintenance.......................................................................................................24
6.3.1. Visual inspections...........................................................................................................24
6.3.2. Detailed visual inspections...........................................................................................24
6.3.3. Bearings............................................................................................................................25
6.3.4. External shaft seal ..........................................................................................................25
6.3.5. Shaft spline ......................................................................................................................25
6.3.6. External cleaning.............................................................................................................25
6.3.7. Re-painting.......................................................................................................................26
7. Spare parts and consumables.................................................................................................................... 27
8. Trouble shooting...........................................................................................................................................28
9. Waste disposal and Recycling ....................................................................................................................30
Appendix 1 Installation check list ...................................................................................................................... 31
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Table of contents

MOTORS FOR HEAVY ELECTRICAL VEHICLES
4
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List of Figures
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List of Tables
Table 1. Explanation of data on rating plate................................................................................................. 10
Table 2. Recommended temperature limits...................................................................................................11
Table 3. Concentricity and perpendicular demands for mating coupling............................................... 16
Table 4. Recommended tightening torques...................................................................................................17
Table 5. High voltage power connector ......................................................................................................... 19
Table 6. Type of low voltage connector ......................................................................................................... 21
Table 7. Recommended mating low voltage connector.............................................................................. 21
Table 8. Inspection and maintenance table...................................................................................................24
Figure 1. Exploded view of the motor................................................................................................................9
Figure 2. Example of rating plate...................................................................................................................... 10
Figure 3. Example of separate rating plate with liquid cooling system data............................................11
Figure 4. The motor is delivered on a pallet.................................................................................................... 12
Figure 5. Position of lifting eye bolts ............................................................................................................... 13
Figure 6. Lifting of motor ................................................................................................................................... 14
Figure 7. Geometrical tolerances for the mating coupling for B14 and B5 mounting............................ 16
Figure 8. Max allowed height difference between D-end and ND-end .......................................................17
Figure 9. Position of liquid cooling inlet and outlet ...................................................................................... 18
Figure 10. Connecting the mating power connector to the motor.............................................................. 19
Figure 11. Location of earth point and low voltage connector. ....................................................................20
Figure 12. 21 pins low voltage connector........................................................................................................... 21
Figure 13. Recommended mating low voltage connector.............................................................................. 21

INTRODUCTION 5
1. Introduction
1.1. General
The purpose of this document is to describe general guidelines for the installation, maintenance and
disposal of the AMXE132 motor.
• Actions shown in this manual are only to be performed by trained personnel authorized by ABB or
authorized by the end user.
The actual appearance of the motor may vary from the illustrations in this manual, depending on the final
design.
Abbreviations and nomenclature used in this manual:
• D-end or DE: Drive side of motor.
• ND-end or NDE: Non drive side of motor.
• WARNING: signal word used to indicate a potentially hazardous situation which, if not avoided, can
result in death or serious injury.
Symbols used in this manual:
Motors for heavy electrical vehicles, type AMXE132
Introduction
3BSY600011-BCM 6 (34)
Chapter 1 Introduction
1.1 General
The purpose of this document is to describe general guidelines for the installation, maintenance
and disposal of the AMXE132 motor.
•Actions shown in this manual are only to be performed by trained personnel authorized by
ABB or authorized by the end user.
The actual appearance of the motor may vary from the illustrations in this manual, depending on
the final design.
Abbreviations and nomenclature used in this manual:
•D-end or DE: Drive side of motor.
•ND-end or NDE: Non drive side of motor.
•WARNING: signal word used to indicate a potentially hazardous situation which, if not
avoided, can result in death or serious injury.
Symbols used in this manual:
Caution, risk of electric shock.
Safety Alert Symbol, warns of a potential personal injury hazard.
Warning, magnetic field.
Prohibition, No access for people with active implanted cardiac devices
(pace maker)
Caution, risk of electric shock.
Motors for heavy electrical vehicles, type AMXE132
Introduction
3BSY600011-BCM 6 (34)
Chapter 1 Introduction
1.1 General
The purpose of this document is to describe general guidelines for the installation, maintenance
and disposal of the AMXE132 motor.
•Actions shown in this manual are only to be performed by trained personnel authorized by
ABB or authorized by the end user.
The actual appearance of the motor may vary from the illustrations in this manual, depending on
the final design.
Abbreviations and nomenclature used in this manual:
•D-end or DE: Drive side of motor.
•ND-end or NDE: Non drive side of motor.
•WARNING: signal word used to indicate a potentially hazardous situation which, if not
avoided, can result in death or serious injury.
Symbols used in this manual:
Caution, risk of electric shock.
Safety Alert Symbol, warns of a potential personal injury hazard.
Warning, magnetic field.
Prohibition, No access for people with active implanted cardiac devices
(pace maker)
Safety Alert Symbol, warns of a potential personal injury hazard.
Motors for heavy electrical vehicles, type AMXE132
Introduction
3BSY600011-BCM 6 (34)
Chapter 1 Introduction
1.1 General
The purpose of this document is to describe general guidelines for the installation, maintenance
and disposal of the AMXE132 motor.
•Actions shown in this manual are only to be performed by trained personnel authorized by
ABB or authorized by the end user.
The actual appearance of the motor may vary from the illustrations in this manual, depending on
the final design.
Abbreviations and nomenclature used in this manual:
•D-end or DE: Drive side of motor.
•ND-end or NDE: Non drive side of motor.
•WARNING: signal word used to indicate a potentially hazardous situation which, if not
avoided, can result in death or serious injury.
Symbols used in this manual:
Caution, risk of electric shock.
Safety Alert Symbol, warns of a potential personal injury hazard.
Warning, magnetic field.
Prohibition, No access for people with active implanted cardiac devices
(pace maker)
Warning, magnetic field.
Motors for heavy electrical vehicles, type AMXE132
Introduction
3BSY600011-BCM 6 (34)
Chapter 1 Introduction
1.1 General
The purpose of this document is to describe general guidelines for the installation, maintenance
and disposal of the AMXE132 motor.
•Actions shown in this manual are only to be performed by trained personnel authorized by
ABB or authorized by the end user.
The actual appearance of the motor may vary from the illustrations in this manual, depending on
the final design.
Abbreviations and nomenclature used in this manual:
•D-end or DE: Drive side of motor.
•ND-end or NDE: Non drive side of motor.
•WARNING: signal word used to indicate a potentially hazardous situation which, if not
avoided, can result in death or serious injury.
Symbols used in this manual:
Caution, risk of electric shock.
Safety Alert Symbol, warns of a potential personal injury hazard.
Warning, magnetic field.
Prohibition, No access for people with active implanted cardiac devices
(pace maker)
Prohibition, No access for people with active implanted cardiac devices (pace maker).

MOTORS FOR HEAVY ELECTRICAL VEHICLES
6
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.
These instructions only consider those measures which must be observed when the motor is being
operated in its operative range and in its intended application. The applicable national, local and plant
regulations must also be taken into consideration.
1.3. Warranty
The warranty period is 12 months after commissioning but no later than 18 months from the date of
notification of being ready for shipment. An extended warranty can be offered on request.
1.4. Information on electromagnetic compatibility
The user must take precautions during installation and operation in order not to impair the
electromagnetic compatibility.
If it is necessary to replace any anti-interference components, filters or screened cables, the new parts
must be identical to the originals.
1.5. Required qualifications for personnel who
handle the motor
Installation, operation, maintenance and repair work may only be carried out by mechanically and
electrically skilled personnel qualified and properly trained for this work. These persons must be well
informed about the motor, that is, they must have completely read and fully understand the relevant
chapters of these operating instructions.

INTRODUCTION 7
1.6. Safety
The motor is manufactured and intended for use only as prescribed by this manual. Modification,
alteration, or lack of maintenance procedures as described in the service manual may adversely affect the
safety and efficiency of this device. The manufacturer is not responsible for malfunctions that comprise
safety as a result of alteration, use of non ABB replacements parts, neglect or misuse.
Should pre-owned ABB equipment be purchased and reconditioned, the equipment should not be used
until testing and analysis demonstrate that the equipment meets the original or upgraded specifications.
The use of solvents as cleaning agents and the use of lubricants can involve health and/or safety hazards.
The recommended precautions and procedures stated by manufacturers should be followed.
Non-authorized modifications as well as the use of tools, components and auxiliary components not
corresponding to the installation or maintenance instructions exclude any liability of the motor
manufacturer.
The motor has rotating parts and parts which may be spinning even at rest, and possibly hot surfaces.
1.7. Contraindications
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.

MOTORS FOR HEAVY ELECTRICAL VEHICLES
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2. Product description
The motor is an AC eight (8) 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.
Special efforts have been made to decrease harmonic losses, noise and torque pulsations. The insulation
system contains corona resistant materials, has low water absorption properties and complies with
temperature class H.
Standard features (options are available)
• 3-phase permanent magnet synchronous motor
• Inverter adapted design of active material
• Class H insulation system
• Temperature sensors inside the stator winding
• Operating ambient temperature between -20°C and +40°C
• Liquid cooled design
• Protection class for the motor, IP65
• Surface treatment, C3-M according to ISO12944-6
• RAL 9005

PRODUCT DESCRIPTION 9
Item no. Designation
External shaft seal
Flange end-shield
Rating plate
LV Connector
HV Connector
Separate rating plate with liquid cooling system data
Side supports
NDE bearing
Shaft spline
 DE bearing
Figure 1. Exploded view of the motor.

MOTORS FOR HEAVY ELECTRICAL VEHICLES
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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. Example of rating plate.
Position Explanation
Applicable standard
Type of motor
Year of manufacture
 
Direction of shaft rotation with default phase order. Seen from D-end
Type designation
Maximum ambient temperature
 
 
 Serial number
 Rated voltage
 Connection
 Rated frequency
 Rated power
 Rated speed
 Rated current
 Rated power factor
 
 
 Stall current 
 Product code
 Maximum rotation speed
 Bearing D-end
 Bearing N-end
 Motor weight
Table 1. Explanation of data on rating plate.
1
Only applicable for cUL certified motors