ABB AMXE250 User manual

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MANUAL
Motors for heavy electrical vehicles
AMXE250

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 AMXE160 without ABB’s written
permission. The contents thereof must not be imparted to a third
party nor be used for any unauthorized purpose.
©Copyright 2022 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. Manual and related documents ...................................................................................................... 7
1.7. Safety................................................................................................................................................... 7
1.8. 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 corrosion protection before commissioning........................................................ 15
3.4. Insulation resistance check ........................................................................................................... 15
4. Motor installation.......................................................................................................................................... 16
4.1. Preparation and lifting ................................................................................................................... 16
4.2. Installation of coupling .................................................................................................................. 16
4.3. Installation of motor........................................................................................................................17
4.3.1. Flange mount....................................................................................................................17
4.3.2. Side mounts......................................................................................................................17
4.4. Liquid cooling system installation ............................................................................................... 18
4.5. Electrical installation ...................................................................................................................... 19
4.5.1. Connection of power supply.........................................................................................20
4.5.2. Earth point ....................................................................................................................... 21
4.5.3. Auxiliary connection ....................................................................................................... 21
5. Operation........................................................................................................................................................22
5.1. Failure mode operation..................................................................................................................22
6. Inspection and maintenance ......................................................................................................................23
6.1. Inspection and maintenance intervals ........................................................................................24
6.2. Inspection and maintenance actions ..........................................................................................24
6.2.1. Visual inspection.............................................................................................................24
6.2.2. Detailed visual inspection.............................................................................................24
6.2.3. Bearings............................................................................................................................25
6.2.4. External shaft seal ..........................................................................................................25
6.2.5. Shaft spline ......................................................................................................................25
6.2.6. External cleaning.............................................................................................................25
6.2.7. Touch-up painting...........................................................................................................26
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Table of contents

MOTORS FOR HEAVY ELECTRICAL VEHICLES
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List of Figures
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List of Tables
Table 1. Legend to exploded view....................................................................................................................9
Table 2. Explanation of data on rating plate................................................................................................ 10
Table 3. Recommended temperature limits .................................................................................................11
Table 4. Electrical connectors......................................................................................................................... 19
Table 5. Inspection and maintenance intervals ..........................................................................................24
Table 6. List of consumables............................................................................................................................ 27
Figure 1. Exploded view of the motor. ...............................................................................................................9
Figure 2. Rating plate example, not to scale. ................................................................................................. 10
Figure 3. Rotor shaft locking during transportation and storage. ............................................................ 12
Figure 4. Position of lifting eye bolts. ............................................................................................................. 13
Figure 5. Lifting of the motor. ...........................................................................................................................14
Figure 6. Removing the rotor shaft locking device........................................................................................ 16
Figure 7. Available installation interfaces seen from D-end. ........................................................................17
Figure 8. Position of liquid cooling inlet and outlet. ..................................................................................... 18
Figure 9. Motor electrical connection interfaces........................................................................................... 19
Figure 10. Example of typical cable arrangement............................................................................................20
Figure 11. Connecting the mating power connectors to the motor. ........................................................... 21
Figure 12. Auxiliary connectors, motor seen from N-end. ............................................................................. 21
7. Spare parts and consumables.................................................................................................................... 27
7.1. Spart parts........................................................................................................................................ 27
7.2. Consumables.................................................................................................................................... 27
8. Trouble shooting...........................................................................................................................................28
9. Waste disposal and recycling .....................................................................................................................30
10. Final comment ............................................................................................................................................... 31
Appendix....................................................................................................................................................................32

INTRODUCTION 5
1. Introduction
1.1. General
The purpose of this document is to describe general guidelines for installation, maintenance and
disposal of the AMXE250 motor.
• Actions shown in this manual are only to be performed by trained personnel authorized by ABB or
trained and skilled personnel authorized by the end user.
The actual appearance of the traction motor may vary from the illustrations in this manual, depending on
optional features of the product.
Abbreviations and nomenclature used in this manual:
• D-end or DE: that end of the machine which accommodates the shaft end. IEC 411-43-36.
• ND-end or NDE: that end of the machine opposite to the drive end. IEC 411-43-37.
• WARNING: signal word used to indicate a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
Symbols used in this manual:
Warning; Electricity, to warn of electricity. Hazard of electric shock.
General warning sign, to signify a general warning. 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, to warn of a magnetic field. Hazard for strong magnetic
field.
Warning; Hot surface, to warn of a hot surface. Hazard of hot surface(s).
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)
No access for people with active implanted cardiac devices, to prohibit people with
active implanted cardiac devices from entering a designated area. Hazard of
interference to the operation of or damage to active implanted cardiac devices from
equipment generating strong electromagnetic fields.

MOTORS FOR HEAVY ELECTRICAL VEHICLES
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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 the following 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
conversant with the motor, that is, they must have completely read and fully understand the relevant
chapters of these operating instructions.

INTRODUCTION 7
1.6. Manual and related documents
• Data sheet, 8AMF500032
• Outline drawing, 3BSM625000-4
• Circuit diagram, 3BSM625000-10
1.7. 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 traction motor has rotating parts and parts which may be moving even at rest, and possibly hot
surfaces.
1.8. 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 without damages caused by improper handling or lack of maintenance according to
instructions in this document. .
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 six (6) 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
• Rotor balance grade G2.5 according to ISO 21940-11
• Operating ambient temperature between -20°C and +40°C
• Liquid cooled design
• Protection class for the motor, IP66
• Surface treatment, C3-M according to ISO12944-6
• RAL 9005
• Hazardous Voltage Interlock Loop (HVIL) function

PRODUCT DESCRIPTION 9
Figure 1. Exploded view of the motor.
Item no. Designation
External shaft seal
Flange D-end shield
Nameplate
Auxiliary connectors
Power supply connectors
N-end bearing
Side mounts
Shaft splines
D-end bearing
Table 1. Legend to exploded view, Figure 1.

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 name plate can be seen in Figure 2.
Figure 2. Rating plate example, not to scale.
Position Explanation
Applicable standard
Type of motor
Year of manufacture
Direction of rotation
 
 
 
 
Connection
 Motor weight
 N-end bearing
 D-end bearing
 Maximum rotational speed
 Variant codes (options)
 Product code
 Stall current 1
 
 Rated point
 Serial number
 Maximum ambient temperature
 Type code
Table 2. Explanation of data on rating plate.
1 Only appliable for cUL certifed motors.