bsr series
TRANSCRIPT
PRODUCTS &SOLUTIONS
BSR SeriesIE2-IE3-IE4
Synchronous Reluctance Motors
3
4 BSR series
5 BSR power drive system
6 Standard and directives
7 Efficiencyclassesandtestmethod
8 Symbolsandunitsofmeasure
9 Termsanddefinitions
10 Thesynchronousreluctancedrivesystem
12 SelectingtheBSRmotor
14 SelectingActiveCube410forBSRmotor
15 Ratingplate
16 BSRSeriesdesignation
18 Technicaldata
19 Torque-speedcharacteristic
20 Dimensionaltolerances
20 Bearings
21 Shaftloads
22 Flangeversions
22 Ventilation
23 Degreeofprotection
24 Insulationclass
24 Thermalprotection
25 Mountingpositions
26 Anti-condensationheaters
26 Secondshaftextension
27 Externalmechanicalprotection
27 Terminalbox
28 Dimensions
31 TheBSRgearmotorpackage
32 Powerdrivesystemenergyefficiency
34 BonfiglioliWorldwidePresence
Index
4
Thesynchronousreluctancemotorisanelectricmotorthatcombinesaconventionalthreephaseinductionmotorstatorwithaninnovativerotordesign.Therotorisdesignedwithamagneticanisotropyresultinginthereluctanceprinciplefortheelectromagneticenergyconversionwithoutusingpermanentmagnetsor rotorwindings. The rotordesignwith the laminationholes yields a lower inertia andbetter dynamics incomparisonwithaninductionmotorofthesamesize.
Thereductionofrotorlossesallowsanincreaseofmotorratingsincomparisonwithaninductionmotorintermsofbothefficiencyandpowerdensity.Takingtheadvantageofthisessentialfeature,BonfiglioliisabletooffertwodistinctiveversionsinBSRsynchronousreluctancemotorseries.TheHighEfficiency(E)versionischaracterizedbytheSuperPremiumIE4EfficiencyClasslevelatalltheratedoperatingpoints,includingthoseinthepartialloadrange.TheHighOutput(O)versionallowstoreducethemotorsizeincomparisonwithaninductionmotorofthesameoutputpower,maintaininganefficiencylevelequalorhigherthantheIE2EfficiencyClass.Whencomparedtohighefficiencyinductionmotors,thedynamicperformancesaresignificantlyhigher,thankstothelowerrotorinertia.
Key benefits• Efficient and Reliable: - Competitive advantagesintermsofTotalCostofOwnership - Highest energy efficiencysystemIES2andenvironmentallyfriendlysolution - Highlevelsofreliabilityduetoourproductionqualityprocessesandinternalknow-how• Dedicated to your application: - BSRmotorsaredesignedtoreplaceinductionmotorsinvariablespeedapplications,ensuring: > Energy efficiency increase up to class IE4ifcomparedwithinductionmotors >Areduction of the motor frameuptotwosizeswiththesamepowerofaninductionmotor - BSRmotors,incombinationwithActiveCube(ACU)410,provideaccurate speed, torque control - Suitable for any variable speed applications,whetherquadraticorconstanttorque Typicalapplicationsare:pumps,fans,compressors,conveyorsandwindingmachines• Wide power range: - 0.37…18.5kW• Accurate sensorless speed control: - BSRincombinationwithActiveCube410providesexcellentmotorcontrolwithoutencoderfeedbacks
Key features• High energy efficiencyofthemotoruptoclassIE4thatleadtoaremarkableenergysaving.• Extremelyhigh efficiencyfromthepartialloadrangeuptotheratedoperatingpoint• Higher torque densityincomparisonwithaninductionmotorofthesamesize• High dynamic responsethroughoptimizedcontrolandlowintrinsicmomentofinertia• High reliability and longer bearings lifethankstoloweroperatingtemperature• High overload capability:Upto300%ofratedtorque• Effective torque and speed control(alsoatlowspeed)withoutencoder• PerfectforretrofitthankstoIECmechanicaldimensions• OptimizedcompatibilitywithActive Cube 410driveseries.
Areas of application:
BSR series•SynchronousReluctancemotor Economicallyandenvironmentallysustainableinnovation
IllustrationofthesectionofaBonfigliolisynchronousreluctancemotorBSR(left)incomparisonwiththeoneofaninductionmotor(right).
FOOD & BEVERAGE
PACKAGINGMATERIALHANDLING
TEXTILE
5
TheBSRserieshasbeenspecificallycoordinatedandharmonizedwithActiveCube410frequencyinverterstodeveloptwosynchronous
reluctancepackages,onefocusedonenergyefficiencyandtheotheronefocusedonhighpowerdensity.
When comparing the synchronous reluctancemotor technology and the inductionmotor technology, themain advantagesof the two
packagesproposedbyBonfiglioliare:
• High Efficiency Package:higherefficiencyclass(uptoIE4)comparedtoaninductionmotorwiththesamepowerandframesize
ThankstoitsPremiumEfficiencyclassIE4,thispackageensuresaremarkabledecreaseintheenergyconsumption,whileensuringhigher
dynamicsincomparisonwithinductionmotorsduetolowerrotorinertia.
Thissolutioncontributestotheincreaseofthemachinereliability,thankstotheabsenceofrotor lossesandlessheatingdissipation,
leadingalsotoalongerlifetimeofbearings.
ThispackageisalsosuitableforinductionmotorsreplacementsincetheBSRmotorsaredesignedwiththesameframesizeasanIE2
inductionmotorofthesamepower.Hence,upgradingtothehighestefficiencylevelresultsinaneasyandsmoothprocess,withoutthe
needformechanicalmodifications.
TheHighEfficiencypackageisparticularlysuitedforthereplacementofinductionorPMmotorsinVariableSpeedDriveapplicationsand
forbasicapplicationssuchasPumps,Fans,Conveyors,Mixers,Dozers.
• High Output Package:smallerframeforsameoutputpowerandefficiencyclassofaninductionmotor
TheHighOutputmotor-drivepackageenablesthereductionofthemotorsizeuptotwoframesizes,oroptionally,theincreaseofthe
powerratingbetween20and100%forthesamemotorframe.
TheHighOutputmotorshaveIECdesignframeandmatcheswithstardardIECgearboxesonthemarket.
TheHighOutputpackageisparticularlysuitedforthereplacementofinductionorPMmotorsinVariableSpeedDriveapplicationsandfor
applicationswhichrequireaccuratesensorlessspeedandtorquecontrol.
Thetwodifferentpackagesensuretherightsolutionforhighefficiencyandcompactapplicationrequirements.
BSR power drive system
BSR 80C O 15-1.5kWIE2EfficiencyClass BE 90LA 4-1.5kWIE2EfficiencyClass
1 frame size less-35% Rotor inertia
Same efficiency class
BSR 90L E 15-1.5kWIE4EfficiencyClass BE 90LA 4-1.5kWIE2EfficiencyClass
Same frame size-24% Rotor inertia+5.4% Efficiency
6
BSRmotorsaremanufacturedinaccordancewithapplicableStandardsandDirectivelistedonthispage.
Standard and directives
BSRmotorsmeettherequirementsofDirectives2006/95/EC(LowVoltageDirectiveCEmarkisappliedtothisproduct).
Directives
STANDARD TITLE STANDARD TITLE
Generalrequirementsforrotatingelectricalmachines IEC60034-1
Terminalmarkinganddirectionofrotationofrotatingmachines IEC60034-8
Methodsofcoolingforelectricalmachines IEC60034-6
Dimensionsandoutputratingsforrotatingelectricalmachines IEC60072
Classificationofdegreeofprotectionprovidedbyenclosuresforrotatingmachines IEC60034-5
Noiselimits IEC60034-9
Classificationoftypeofconstructingandmountingarrangements IEC60034-7
Vibrationlevelofelectricmachines IEC60034-14
EfficiencyclassesofvariablespeedACmotors(IEcode) IECTS60034-30-2
Specifictestmethodsfordetermininglossesandefficiencyofconverter-fedACmotor IEC60034-2-3
Standard
7
Thestandard IEC60034-2-3definesthetestmethodsfordeterminingtotal losses includinghigh frequencymotorlossesandefficiencyoffrequencyinverterdrivenmotors(1).ForinverterdrivenmotorsliketheBSRmotorseries,theinput-outputmethodisapplied.Thestandarddefinessevenstandardizedoperationpointstocharacterizemotorlossesandefficiencyalongthecompletetorque-speedrange.Furthermore,theIEC60034-2-3providesaninterpolationprocedureforthelossdeterminationinanyoperatingpoint.
ThestandardIEC60034-30-2definestheinternationalenergy-efficiencyclassofvariablespeedACmotors.Theefficiencyclasses(IEcode)rangefromIE1(Standardefficiency)toIE5(UltraPremiumefficiency).
European Commission regulation 640/2009IEC standard 60034-30-2 establishes technical guidelines for efficiency classification but does not imposeany legalrequirements fortheadoptionofanyparticularefficiencyclass.Theseare laiddownbyEuropeanDirectivesandnationallaws.TheECRegulationapplyingDirective2009/125/ECwasadoptedonthe21stOctober2009.Thisestablishesthelegalrequirementsandeco-compatibledesigncriteriaforinductionmotors,andimposesminimumefficiencylimitsaccordingtothefollowingschedule:• 16/06/2011:InductionmotorsmusthaveaminimumefficiencylevelequivalenttoclassIE2• 01/01/2015:Inductionmotorswitharatedpoweroutputbetween7.5kWand375kWmusthaveaminimum efficiencylevelcorrespondingtoIE3,ortoIE2ifcontrolledbyafrequencyinverter• 01/01/2017:Inductionmotorswitharatedpoweroutputbetween0.75kWand375kWmusthaveaminimum efficiencylevelcorrespondingtoIE3,ortoIE2ifcontrolledbyafrequencyinverter
BSRmotorsincombinationwithActiveCube410frequencyinverterseriesmeetorexceedthelegalrequirementsforenergyefficiencyandareclassifieduptoclassIE4.
BSRmotorsarenotsubjecttoanyminimumefficiencyrequirementsforspecificcountries.
Efficiency classes and test method
STANDARDIZED OPERATING POINT
n T P
p.u. values refer to the nominal values
P1 0.9 1 0.9
P2 0.5 1 0.5
P3 0.25 1 0.25
P4 0.9 0.5 0.45
P5 0.5 0.5 0.25
P6 0.5 0.25 0.125
P7 0.25 0.25 0.0625
Torque[p
.u.]
Speed[p.u.]
00.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
0.5
0.25
0.75
1.0(3)
(7)
(2)
(5)
(6)
(4)
(1)
(1) IEC 60034-2-3 uses “converter” as a term for frequency inverters.
8
Symbols and units of measure
SYMBOL U.M. DESCRIPTION
η4/4 [-] EfficiencyatPn
fH [-] Altitudeadjustmentfactor
fn [Hz] Ratedfrequency
fT [-] Temperatureadjustmentfactor
In [A] Ratedcurrent
Iol [A] Overloadcurrent
Ip [A] Peakcurrent
Jm [kgm2x10-4] Motormomentofinertia
mIM B5 [kg] MasswithIMB5mounting
MEQU [Nm] Equivalenttorque
Mn [Nm] Ratedtorque
Mol [Nm] Overloadtorqueatnn
Mp [Nm] Peaktorque
nn [min-1] Rated speed
nmax [min-1] Maximumspeed
Pn [kW] Rated power
Unless otherwise specified, all dimensions are expressed in millimeters.
9
Duty type S1:Operationatconstantloadmaintainedforsufficienttimetoallowthemachinetoreachthermalequilibrium.
Duty type S3:sequenceofidenticaldutycycles,eachincludingatimeofoperationatconstantloadandatimede-energizedandatrest.Ifnotspecifiedthecycletimeisfixedequalto10minutes.
Electric time constant [τel]:isthetimetakenforthecurrenttoreach63.2%ofitssteadystatevaluewhenastepinputvoltageisappliedwhiletherotorisstationary.Itiscalculatedbydividingthewindingphase-to-phaseinductance(Lpp)bythewindingphase-to-phaseresistance(Rpp)at20°C.
Terms and definitions
τel=Lpp/Rpp
tf Worktimeunderconstantloadtr Rest time
Intermittence:
I = ∙ 100tf
tf + tr
P[kW]
t[°C]
tc
tf tr
t
Rated speed [nn]:isthespeedatwhichthemotorhasbeendesignedtooperatewithareasonablelevelofcontrol,intermsofoverloadtorque(Mol)andoverspeed.
Rated torque [Mn]:isthethermallypermissiblecontinuoustorqueforS1dutyattheratedmotorspeed(nn).
Thermal equilibrium:isthestatereachedwhenthetemperatureriseoftheseveralpartsofthemachinedonotvarybymorethanagradientof2Kperhour.
Thermal time constant [τtherm]:isthetimeforthetemperaturetoreach63.2%ofthisfinalvaluebetweenthemotorhousingandtheambientafterastep-wisecurrentchange.
Winding temperature rise [dT]:isthetemperaturerise,inspecifiedserviceconditions,ofthemotorwindingsabovethemaximumambientreferencetemperature.
Rated power [Pn]:isthemechanicalpoweravailableatshaftatratedspeednn.
Peak current [Ip]:isthecurrentusedtoproducethepeaktorque(Mp).Itisthecurrentlimitofthemachine,andifexceeded,evenforashortperiod,anirreversibledamagetothemachinecanoccur.
Peak torque [Mp]:istheabsolutemaximumtorquethatcanbeproducedbyamotorforashorttime.
Rated current [In]:istheRMScurrenttoproducetheratedtorque(Mn).
Overload current [Iol]:istheRMScurrenttoproducetheoverloadtorque(Mol)atratedspeed(nn).
Overload torque [Mol]:istheoverloadtorqueatratedspeed(nn).
Rated frequency [fn]:isthefrequencyofthefundamentalcomponentoftheoutputvoltagecorrespondingattheratedspeed(nn)accordingtothefollowingequationwherepisthepolepairs.
fn = p ∙ nn/60
Pn = 2π ∙ Mn ∙ nn /60
10
The synchronous reluctance drive systemSmartmotorcontrolforyourapplication
FLEXIBLE CONTROL STRATEGIES
ParameterIdentification
StartingOptions
Rotor Position Control
FluxControl
Optimized control for best PERFORMANCE and EFFICIENCY
Nom.Speed&Const.Torque
Range
HighSpeed&Const.
PowerRange
StartwithCurrentInjection
StartwithSensorless
FieldOrientedControl
SensorlessStartwithFeedback#
SensorBased#
Improved EfficiencywithMTPATable
OperationatVoltageLimit
Standard OptionforAcceleration
Ramps
AtfastAcceleration
Ramps
FundamentalModelwithImpedance
Map
Ifimplemented
Beneficialatverylow
Speed
TheBSRmotorsareoptimizedforoperatingwithActiveCube410inverterseries.ThankstothemotordataintegrationintheinvertersoftwareVPlus,thesetupisextremelyfastandeasy.TheresultingpowerdrivesystemmeetsalltherequirementsfortheIES2topefficiencyclassification.
Active Cube 410 Series
Power range:from0.25kWto400kW
Overload capacity• upto150%for60seconds• upto200%for1second
Motor Control(openlooporoptionalclosedloop):• AsynchronousACmotors• Synchronousreluctancemotors• Permanentmagnetsynchronous(brushless)motors
Communication modules• DifferentfieldbusoptionslikeCANopen,PROFIBUS,Modbus,EtherCAT,PROFINET,Varan• OptionalI/Oextensionsforaddtionaldigitalandanalogueinputs&outputs
# on request
11
The synchronous reluctance drive system guarantees excellent control performance thanks to optimized,model-basedsensorlesscontrol.
ThededicatedActiveCube410motorcontrolallowstooperatetheBSRmotorwiththesefeaturesandbenefits:•Exploitthemaximumpeaktorqueanddynamicthankstoaprecisefluxcontrol,•Maximizethemotorefficiencyevenatpartialloadthankstotheimplementedmotormodel,•Takeadvantageofthefieldweakeningcontrolathighspeed.
The synchronous reluctance drive systemIncreaseyourmachineproductivity
Flux Control Benefits: ExtractingMaximumTorque
Capability•EfficiencyOptimisation•FieldWeakening
ComprehensiveControlStructureforFlexibleAdaptiontoCountlessApplications
Field Oriented Sensorless Control:• Precisecontrolwith accuratemachinemodel• AchievingDynamicswith AdvancedMotorModel
Start-Up Manager:• NominalTorqueavailableat f=0Hz• VariousOptionsforany Application
SpeedReference
Ref.Flux
Est.Flux
Est.Speed
i
id
i*
u*
iq
u*
FieldWeakening
NominalSpeedRange
FieldController
SpeedController
CurrentController
Start-UpManager•CurrentInjection•FieldOrientedStart•Startwithmotorfeedback#
AdvancedMotorModel
Impedance Map
VoltageLimitOperation
OptimizedFluxTable
FluxEstimation
AngleEstimation
Sensorless Reluctance Motor Control with Active Cube 410
#oncustomerrequest
12
Selecting the BSR motor
(a) Equivalenttorque MEQU [Nm]
(b) Temperatureadjustingfactor fT -
(c) Altitudeadjustmentfactor fH -
(d) Equivalentcurrent IEQU [A]
13
Selecting the BSR motor
Select a bigger motor size
NO
NO
NO
START
END
Selecttherequiredmotorversion:E-HighefficiencyO-Highoutput
From load cycle determine:MaximumtorqueandrelativespeedMaximumspeedandrelativetorque
Select motor size, power rating and nominal speed
Select a bigger motor size
Select a bigger motor size
Calculateequivalenttorque
CalculatefT
CalculatefH
YES
YES
YES
Areallworkingpointsoftheloadcyclebelowthe
motorlimitcurve?
Mn*fT*fH > MEQU
Doesthemotorinertiamatchtheload
inertia?
(a)
(b)
(c)
14
Selecting Active Cube 410 for BSR motor
Select a bigger inverter size
NO
END
YES
IsACU410selectionfittingaccordingtoderating
figures?
Start Simplified Selection ACU410
Determinefromloadcycle:Mmax&tmaxcurrent:Maximumtorque&correspondingtime
MEQU:Equivalenttorque
SelectinverterbasedonImax,tmaxcurrent and IEQUConsidera10%currentreservewhenselectingthe
inverter
DeterminederatingfiguresaccordingtoACU410operatinginstructions*:
Temperature,Altitude,Voltage,SwitchingFrequency
Determinefrommotorselectionandloadcycle:DeterminekT= MN/IN
Imax:MaximumcurrentIMAX = MMAX/kT
IEQU:EquivalentcurrentIEQU = MEQU/kT
*: Derating has to be considered in these cases:More than 40°CMore than 1000 m altitudeMore than 3~ 400 V mains supplyPWM switching frequency 8 kHz or higher
15
InaccordancewithIEC60034-1,themotorratingplatesummarizesthemotorratingincludingthetotalweight.Exampleofratingplateandfield’sdescriptionarereportedhereafter.
Fields:1) Productdesignation2) Productcode3) Serialnumber4) Insulationclass5) Nominalpower6) Totalweight7) Degreeofprotection8) Motormounting9) Dutycycle10)Nominalfrequency11)Nominalvoltageandwindingconnection12)Nominalcurrent13)Nominalefficiencyatfullload14)Nominalspeed15)Maximumspeed16)Maximumambienttemperature17)Optiondata(e.g.fanunitdata)18)Efficiencyclass(IEcode)19)Driveendbearingtype20)Nondriveendbearingtype21)Serialnumberasbarcode
Rating plate
ExampleofBSRratingplate:
16
MOTOR
BSR Series designation
Degree of protection55 IP 55(2)
56 IP 56
Nominal line voltage40 400V(Yconnection)
Motor ratingE HighEfficiency(1)
O HighOutput
Nominal speed15 1500 min-1
30 3000 min-1
Motor typeBSR IEC3-PhaseSynchronousReluctanceMotor
Insulation classF ClassF(2)
H ClassH
BSR 40 FE80B 5515
Motor size71B … 132MB(IECMotor)
17
OPTIONS
Thermal protective devicesK1(5) SiliconsensortypeKTY84-130E3 ThermistorPTCP1 PlatiniumsensorPT1000
Forced ventilationU1(6) Powersupply1~230V(71-100),3~400VY(112-132)
Anti-condensate heatersH1 Powersupply1~230V
Double-extended shaftPS(6)
External mechanical protectionTC(6)
Rotor balancing grade BRV
...
Motor mountingB3 IMB3,IMB6,IMB7,IMB8,IMV5,IMV6B5 IMB5,IMV1,IMV3B14 IMB14,IMV18,IMV19B5R IMB5notstandardized(3)
B14R IMB14notstandardized(4)
B5
Notes:(1) Not available with nominal speed 3000min-1
(2) Default value(3) Flange with through holes with reduced coupling dimensions (4) Flange with tapped holes with reduced coupling dimensions. Not available for motor size 112 and 132 (5) Not compatible with insulation class H (6) Options U1, PS and TC are mutually exclusive
18
Operation with ACU410 frequency inverter series - rated voltage 400V - 1.5xMn overload at nominal speed (Mol) - 3xMn Peak overload (Mp)
4-pole 50 Hz 1500rpm Y Connection
Pn Size - Rating - Speed η4/4 IE Mn In Iol Ip nmax Jm mIM B5Suggested ACU410 inverter with
150% overload for max. 60 s
High Efficiency (E) - S1 duty cycle
kW % Code Nm A A A min-1 kgm2 x10-4 kg
0,37 BSR 71B E 15 81,5 IE4 2,4 1,1 1,5 2,9 2250 8 5,7 ACU410031F…0,55 BSR71C E 15 83,9 IE4 3,5 1,6 2,2 4,1 2250 10 7,1 ACU410031F…0,55 BSR 80B E 15 83,9 IE4 3,5 1,6 2,2 3,6 2250 17 9,5 ACU410031F…0,75 BSR80C E 15 87,0 IE4 4,8 2,2 2,9 5,1 2250 22 12,2 ACU410071F…1,1 BSR 90S E 15 88,3 IE4 7,0 3,0 3,9 7,0 2250 22 13,1 ACU410091F…1,5 BSR90L E 15 88,2 IE4 9,5 4,0 5,5 9,5 2250 26 14,5 ACU410122F…2,2 BSR100LA E 15 89,5 IE4 14,0 5,8 8,0 14,3 2250 45 22 ACU410132F…3 BSR100LB E 15 90,4 IE4 19,1 7,8 11,3 19,8 2250 50 24 ACU410152F…4 BSR 112M E 15 91,1 IE4 25 9,7 13,5 24,7 2250 82 31 ACU410193…5,5 BSR 132S E 15 92,1 IE4 35 13,5 18,8 36 2250 220 51 ACU410193…7,5 BSR132MA E 15 92,7 IE4 48 17,8 25,5 52 2250 255 57 ACU410213…9,2 BSR 132MB E 15 93,0 IE4 59 21,6 32 64 2250 280 67 ACU410223…
High Output (O) - S1 duty cylce
kW % Code Nm A A A min-1 kgm2 x10-4 kg
0,55 BSR 71B O 15 80,8 IE3 3,5 1,7 2,4 4,4 2250 8 5,7 ACU410051F…0,75 BSR71C O 15 82,5 IE3 4,8 2,1 3,4 6,2 2250 10 7,1 ACU410071F…0,75 BSR80A O 15 79,6 IE2 4,8 2,1 3,5 5,9 2250 13 8,0 ACU410071F…1,1 BSR 80B O 15 81,4 IE2 7,0 3,1 4,5 9,5 2250 17 9,5 ACU410091F…1,5 BSR80C O 15 82,8 IE2 9,5 3,9 6,9 10,9 2250 22 12,2 ACU410122F…2,2 BSR 90S O 15 85,9 IE2 14,0 5,6 8,2 16,8 2250 22 13,1 ACU410132F…3 BSR90L O 15 85,5 IE2 19,1 7,6 11,7 24,0 2250 26 14,5 ACU410152F…4 BSR100LB O 15 88,6 IE3 25 10,5 15,3 30 2250 50 24 ACU410193…5,5 BSR 112M O 15 89,6 IE3 35 13,5 19,5 42 2250 82 31 ACU410193…7,5 BSR 132S O 15 91,3 IE3 48 18,4 25,3 52 2250 220 51 ACU410223…9,2 BSR132MA O 15 91,6 IE3 59 22,0 33 66 2250 255 57 ACU410233…11 BSR 132MB O 15 91,5 IE3 70 24,7 32 77 2250 280 67 ACU410233…
Operation with ACU410 frequency inverter series - rated voltage 400V - 1.5xMn overload at nominal speed (Mol) - 3xMn Peak overload (Mp)4-pole 100 Hz 3000rpm Y Connection
High Output (O) - S1 duty cylcekW % Code Nm A A A min-1 kgm2
x10-4 kg
1,1 BSR 71B O 30 85,2 IE4 3,5 3,1 4,5 8,5 4500 8 5,7 ACU410091F…1,5 BSR71C O 30 87,1 IE4 4,8 4,2 6,2 11,7 4500 10 7,1 ACU410122F…1,5 BSR80A O 30 84,7 IE3 4,8 4,1 5,9 11,2 4500 13 8,0 ACU410122F…2,2 BSR 80B O 30 86,3 IE3 7,0 5,8 8,5 16,0 4500 17 9,5 ACU410132F…3 BSR80C O 30 88,3 IE3 9,5 7,8 11,6 19,7 4500 22 12,2 ACU410152F…4 BSR 90S O 30 90,2 IE3 12,7 9,9 15,2 27,3 4500 22 13,1 ACU410193…5,5 BSR90L O 30 90,9 IE4 17,5 13,5 20,6 43 4500 26 14,5 ACU410193…7,5 BSR100LB O 30 91,7 IE4 24 20,0 27,8 56 4500 50 24 ACU410223…11 BSR 112M O 30 91,9 IE3 35 24,5 36 77 4500 82 31 ACU410233…15 BSR 132S O 30 92,0 IE3 48 36 53 107 4500 220 51 ACU410273…18,5 BSR132MA O 30 92,4 IE3 59 43 62 126 4500 255 57 ACU410293…
Technical data
19
ThepermissibleoperatingrangeofaSynchronousReluctancemotor isdefinedbythermal,mechanicalandsensorlesscontrollimit.
ThebehavioroftheBSRsynchronousreluctancemotorisdescribedbyatorque-speedoperatingareaobtainedbythecombinationoftheBSRmotorseriesandtheActiveCube410frequencyinverterseries.Exceedingthenominalspeedthecontinuoustorquecurvedecreasesaccordingtotheconstantpowerlimit.Thecontinuousdutyzoneislimitedbythemaximumcontinuoustorquecurveandthevoltagelimitcurve.ContinuousdutyintheareaabovetheS1curveisnotpermitted.Theintermittentperiodicdutyzoneislimitedbythepeaktorquelineandthevoltagelimitcurve.
ThesignificantworkingpointsusedtodefinetheoperationzoneoftheBSRmotorsarehighlightedinthegraphaboveandthefollowingtable.Thevaluesrefertoratedtorque(Mn)andratedspeed(nn)as“perunit (p.u.)”expression,
(1) The value is valid only for BSR motor with nominal speed 1500 min-1
(2) The value is valid only for BSR motor with nominal speed 3000 min-1
Torque-speed characteristic
Voltagelimit
Torque[N
m]
Speed[min-1] nn nmax
Mp
Mol
Mn
Intermittent Duty
Continuous Duty
BSR ... E
BSR ... O
1
4
2
5
3
6
7
SYMBOL U.M. DESCRIPTION
1 2 3 4 5 6 7
Torque [p.u.] 0.4 1 0.4 1.5 3 3 1.5
Speed [p.u.] 0 0.4(1) 0.2(2) 1.5 0 0.3 0.8 1
Duty - Continuous Intermittent
20
Dimensionsandtolerancesofshaftend,keyandflangeareinaccordancewithIEC60072-1.ShaftendsfeatureanaxialthreadedholeinaccordancewithUNI3221,DIN332andakeyinsertedinthesuitablekeyway.Thefollowingtablereportsthetolerancesforthedifferentparts:
Dimensional tolerances
COUPLING DIMENSION DIMENSIONS RANGE TOLERANCE
Shaftend D - DAØ11-28 j6
Ø38-48 k6
Key F - FA - h9
Flange N Ø < 250 j6
BSRmotorsuseradialballbearings,lubricatedforlifewithgreaseandaxiallypre-loaded.Thetypeofbearingsinusearelistedinthefollowingtable.
(1) Only for the B5R motor mounting variant.
Bearings
SIZE PROTECTION DEGREE IP55 PROTECTION DEGREE IP56
DRIVE END NON DRIVE END DRIVE END NON DRIVE END
BSR 71 62022ZC3 62032ZC3(1) 62022ZC3 62022RSC3 62032RSC3(1) 62022RSC3
BSR 80 62042ZC3 62042ZC3 62042RSC3 62042RSC3
BSR 90 62052ZC3 62052ZC3 62052RSC3 62052RSC3
BSR 100 62062ZC3 62072ZC3(1) 62062ZC3 62062RSC3 62072RSC3(1) 62062RSC3
BSR 112 63062ZC3 63062ZC3 63062RSC3 63062RSC3
BSR 132 63082ZC3 63082ZC3 63082RSC3 63082RSC3
21
Themaxiumradialload(FR)andmaximumaxialload(FA)arecomputedusingISO281calculationL10hassumingabearinglifeof20.000h.Theloadandthespeedareassumedtobeconstantthroughoutthebearinglife.
Themaximumradialloadisreportedasafunctionofthedistance(X)betweenflangeplaneandthepointofforceapplicaton.ThemaximumradialloadsFRarevalidonlyforthehorizontalinstallationofthemotorwithoutadditionalaxialload.
Shaft loads
22
FlangeoutputmotorsareavailablewithreducedcouplingdimensionscorrespondingtoproductvariantsB5R(withthroughholes)andB14R(withtappedholes).Dimensionsareindicatedinthetablebelow:
Flange versions
ThestandardBSRmotorisequippedwithaself-coolingfan(IC411inaccordancewithCEIEN60034-6).Thefanandtheresultingcoolingisoptimizedforratedspeed.Installationmusttakeintoaccountaminimumdistanceofthefancoverfromthenearestwalltoensureunobstructedaircirculation.FormachinesoperatingfrequentlyorforlongperiodsoftimeatsmallspeedstheBSRmotorcanbeequippedwiththeoptionalfanunitU1(referredtoasIC416instandardCEIEN60034-6).TheterminalsoftheU1fanunitarehousedinaseparateterminalbox.
ThefollowingtablesummarizestheelectricaldataofthefanunitU1andtheincreaseofmotorlength.
(1) Dimension variation compared to length LB of the corresponding standard motor.
Ventilation
MOTOR SIZE ELECTRICAL DATA OF FAN UNIT U1 ΔLB(1)
VAC ±10% Hz P [W] I [A] [mm]
BSR 71
1~230
50/60
22 0.12 93
BSR 80 22 0.12 127
BSR 90 40 0.30 131
BSR 100 50 0.25 119
BSR 1123~230Δ/400Y
50 0.26/0.15 130
BSR 132 110 0.38/0.22 161
SIZE D E M N P
BSR 71B5R 11 23 115 95 140
B14R 11 23 75 60 90
BSR 80B5R 14 30 130 110 160
B14R 14 30 85 70 105
BSR 90 B5R 19 40 165 130 200
B14R 19 40 100 80 120
BSR 100B5R 24 50 165 130 200
B14R 24 50 115 95 140
BSR 112 B5R 24 50 165 130 200
BSR 132 B5R 28 60 215 180 250
23
IP55isusedasdefaultprotectionclassfortheBSRmotorconfiguration.OptionallytheprotectionclassIP56isavailableasvariant,pleasechecktheproductdesignation.InaccordancewithIEC60034-5:
Degree of protection
Not protected
ProtectedagainstextraneoussolidbodieshavingØ≥50mm
ProtectedagainstextraneoussolidbodieshavingØ≥12.5mm
ProtectedagainstextraneoussolidbodieshavingØ≥2.5mm
ProtectedagainstextraneoussolidbodieshavingØ≥1.0mm
Nodustingress
Protectedagainstdust
Not protected
Protectedagainstverticalwater drips
Protectedagainstverticalwaterdripsinclinedupto15°
Protectedagainstrain
Protectedagainstwatersplashes
Protectedagainstpowerfuljetsofwater
Protectedagainsttheeffectsoftemporaryimmersion
Protectedagainsttheeffectsofcontinuousimmersion
Protectedagainstjetsofwater
24
BSRmotorsaredesignedaccordingtoclassFinsulatingmaterialsasstandardvariant.OptionallytheinsulationclassHisavailableforBSRmotors.Forapplicationinvolvingthepresenceofaggressivechemicalsorhighhumidity,pleasecontactBonfiglioli.
DuringthecommissioningoftheActiveCube410frequencyinverter,theconnectedBSRmotorissetup.DuringthissetupasoftwareI²tmonitoringisactivatedofferinganinexpensivesolutionforthermalmonitoringwiththepossibilitytosetupafaultswitchoffinsidethefrequencyinverter.OptionallytheBSRmotorcanbeequippedwithahardwarethermalswitchthatcanbeevaluatedwiththeActiveCube410.Ahardwaremonitoringisespeciallyrecommendedformotorswithforcedventilation(U1option).Theavailablethermalswitchesare:
Insulation class
Thermal protection
F H
Hottestpointmarginwithtemperaturedeterminationbyresistancemethod
Increaseallowedbythetemperature
Max.ambienttemperature
OPTION THERMAL SWITCH DESCRIPTION
K1 TypeKTY84-130
AKTYsiliconsemi-conductorresistancesensorisplacedincontactwiththemotorwinding.Theworkingtemperaturerangeisfrom0°Cto170°C.ThissensorcannotbeusedincombinationwithinsulationclassH.
E3 PTC
3PTCthermistorsareplacedincontactwiththemotorwinding.Thethermistorswitchtemperatureisinaccordancewiththeinsulationclassofthemotor.ForthePTCthermistorresistancecurvepleaserefertotheStandardDIN44081-82.
P1 PT1000
Aplatinumresistancetemperaturesensorisplacedincontactwiththemotorwinding.ThePT1000characteristicisinaccordancewithIEC60751:2008,toleranceclassB.Theworkingtemperatureisfrom-40°Cto250°C.
25
EC-normalisedBSRmotorsareavailableinthedesignversionsasindicatedinthefollowingtableaccordingtoStandardsEN60034-7.
BSRisavailablewiththefollowingmountingversions:IM B3(basic)IMB6,IMB7,IMB8,IMV5,IMV6(derived)IM B5(basic)IMV1,IMV3(derived)IM B14(basic)IMV18,IMV19(derived)
IMB3designmotorscanbeinstalledinpositionsIMB6,IMB7,IMB8,IMV5andIMV63;IMB5designmotorscanbeinstalledinpositionsIMV1andIMV3;IMB14designmotorscanbeinstalledinpositionsIMV18andIMV19. Insuchcases,thebasicdesignIMB5orIMB14isindicatedonthemotornameplate.
Mounting positions
26
Whereanapplication involveshighhumidityorextremetemperaturefluctuations,motorscanbeequippenoptionallywithananti-condensationheater(optionH1).Asingle-phasepowersupplyisavailableintheauxiliaryterminalboardinsidethemainterminalbox.Thefollowingtablesummarizestheelectricalpropertiesoftheanti-condensationheater.
Anti-condensation heaters
VOLTAGE POWER
[V] [W]
BSR71-BSR801~230±10%
10
BSR90…BSR132 25
Second shaft extension
AsecondshaftextensionisavailableselectingtheoptionPS.ThisoptioncannotbeusedincombinationwithoptionsU1orTC.Theshaftdimensionscorrespondtothefirstshaftandaresummarizedinthedimensionstableinthiscatalogue.
27
Terminalboardfeatures6studsforeyeletterminalconnections.Agroundterminalisalsosuppliedforheartingoftheequipment.Terminalnumberanddimensionareshowninthefollowingtable.InmotordesignIMB3,theterminalboxisonthetop(sideoppositetofeet).
ThecableentriesoftheterminalboxesusemetricthreadsinaccordancewithstandardEN50262asindicatedinthefollowingtable.
Terminal box
BSR SIZE NUMBERS OFTERMINALS
TERMINALTHREADS
WIRE CROSSSECTION AREA
[mm2]
BSR71…BSR906
M4 2.5
BSR100…BSR132 M5 6
BSR SIZE CABLE GLAND AND DIMENSIONS MAXIMUM CABLEDIAMETER ALLOWED
[mm]
BSR 71 2xM25x1.51Holeoneachside
17
BSR80...BSR90 2xM25x1.5 17
BSR100...BSR112 2xM32x1.52xM25x1.5 2Holesoneachside
2117
BSR 132 4xM32x1.5 21
Inapplicationswithhigh riskofobstructionsof the fan (i.e. flying lints in textile industryenvironments) theoptionTC(textilecanopy)canbeaddedasoption.Thefollowingtablesummarizesthedimensionspermotorsize.
AQ ΔV
BSR 71 134 27
BSR 80 152 25
BSR 90 168 30
BSR 100 190 28
BSR 112 211 32
BSR 132 254 32
External mechanical protection
28
Dimensions
B3
SHAFT
D DA E EA DB GA GC F FA
BSR 71 14 30 M5 16 5
BSR 80 19 40 M6 21,5 6
BSR 90 24 50 M8 27
5BSR 10028 60 M10 31
BSR 112
BSR 132 38 80 M12 41 10
HOUSING B3
B A HA BB AB K C H
BSR 71 90 112 8 112 135 45 71
BSR 80100
125 8 124 153
10
50 80
BSR 90 S140 8 155 174 56 90
BSR 90 L 125
BSR 100140
16010 175
192
12
63 100
BSR 112 190 224 70 112
BSR 132 178 216 12 218 254 89 132
MOTOR
AC L LB LC AD AF LL V
BSR 71 138 249 219 281 10874 80
37
BSR 80 156 274 234 315 119 38
BSR 90 176 326 276 378 133
98 98
44
BSR 100 195 367 307 429 142 50
BSR 112 219 385 325 448 157 52
BSR 132 258 493 413 576 193 118 118 58
EA: Second shaft available as option
29
Dimensions
B5
SHAFT
D DA E EA DB GA GC F FA
BSR 71 14 30 M5 16 5
BSR 80 19 40 M6 21,5 6
BSR 90 24 50 M8 27
5BSR 10028 60 M10 31
BSR 112
BSR 132 38 80 M12 41 10
HOUSING B5
M N P S T LA
BSR 71 130 110 160 9.5
3.5
10
BSR 80165 130 200 11.5 11.5
BSR 90
BSR 100215 180 250
14 4
14
BSR 112 15
BSR 132 265 230 300 20
MOTOR
AC L LB LC AD AF LL V
BSR 71 138 249 219 281 10874 80
37
BSR 80 156 274 234 315 119 38
BSR 90 176 326 276 378 133
98 98
44
BSR 100 195 367 307 429 142 50
BSR 112 219 385 325 448 157 52
BSR 132 258 493 413 576 193 118 118 58
EA: Second shaft available as option
30
Dimensions
B14
SHAFT
D DA E EA DB GA GC F FA
BSR 71 14 30 M5 16 5
BSR 80 19 40 M6 21,5 6
BSR 90 24 50 M8 27
5BSR 10028 60 M10 31
BSR 112
BSR 132 38 80 M12 41 10
HOUSING B14
M N P S T
BSR 71 85 70 105M6
2.5
BSR 80 100 80 1203
BSR 90 115 95 140
M8BSR 100130 110 160 3,5
BSR 112
BSR 132 165 130 200 M10 4
MOTOR
AC L LB LC AD AF LL V
BSR 71 138 249 219 281 10874 80
37
BSR 80 156 274 234 315 119 38
BSR 90 176 326 276 378 133
98 98
44
BSR 100 195 367 307 429 142 50
BSR 112 219 385 325 448 157 52
BSR 132 258 493 413 576 193 118 118 58
EA: Second shaft available as option
31
The BSR gearmotor package
Control, flexibility, efficiency and compactness are fundamental characteristics in a wide range of industrialprocessesandapplications.Tomatch these needs Bonfiglioli has developed a new solution, represented by the Bonfiglioli synchronousreluctancemotor(BSR),combinedwiththehelicalorwormtechnologyofBonfiglioliA,C,F,SandVF-Wgearunits.ThesynergybetweenBSRmotorsandA,C,F,SandVF-WgearboxesallowstoexploittherobustnessandwidetorquerangeofBonfiglioli industrialgearunits,aswellas theflexibilityandefficiencyofBonfiglioli reluctancemotors.
Maximum FlexibilityTwodifferentsolutionsavailable:•HighEfficiencyPackage:BSRinIE4efficiencyclasscombinedwithA,C,F,Sgearboxes•HighOutputPackage:BSRinIE2,IE3,IE4efficiencyclasscombinedwithA,C,F,SandVF-Wgearboxes
ModularityThemodularcouplingbetweenBSRandBonfiglioligearboxesguaranteesextendedcustomizationcapability.Indeed,thefullrangeofversionsandoptionsoftheA,C,F,SandVF-Wgearboxes,canbeusedtocustomizethesolutionandperfectlymatchcustomers’needs.
One stop shopAll the componentsof thedrivepackagearemanufacturedbyBonfiglioli. This ensures thehighest levelofperformancesandcompatibility.Atthesametimeourcustomerscanrelyonauniquesupplierforallgearboxes,motorsandinverters.
Areas of Application
PACKAGING RORATYTABLE
ROTARYMACHINES
PICK & PLACE SOLUTIONS
MATERIALHANDLING
32
TheinternationalstandardIEC61800-9dealswiththeenergyefficiencyofcompletedrivemodules(CDM)andpowerdrivesystems(PDS).ThestandardIEC61800-9isharmonizedinEuropeasEN61800-9andreplacestheearlierstandardEN50598(-1and-2).Asrepresentedinthefollowingdiagram,thepowerdrivesystemconsistsofthecompletedrivemoduleandtheelectricalmotor,includingthemotorcable.ThestandarddefinestheIEclassesforCDMandtheIESclassesforPDS.
TheIECstandard61800-9-2specifiestheprocedurefordeterminingthe lossesofthePDSin8application-relevantoperatingpointsformotordriveapplicationsinthepowerrangefrom0.12kWto1,000kW.Lossesof the referencepowerdrivesystem (RPDS)aredefined for the8specificoperatingpointsand theinternationalefficiencyofsystemsclasses(IES)forthePDS.ThePDSenergyefficiencyisclassifiedintherangeofIES0-IES2asdescribedinthefollowingillustration.
Illustrationoftheoperatingpoints(shaftspeed,torque)forthedeterminationoftherelativelossesofthePDSaccordingtoIEC61800-9-2.
IllustrationoftheIESclassesofaPDSaccordingtoIEC61800-9-2.
Power drive system energy efficiency
PDS
Electricpowerfrommains
Motorelectricpower
Mechanicalpoweronshaft
CDMlosses Motorlosses
MainsSupply CDM Motor Load
PDSrelativetorque(%
)
PDSrelativespeed(%)50 100
50
25
100pL,PDS(0;100)
pL,PDS(0;50)
pL,PDS(0;25) pL,PDS(50;25)
pL,PDS(50;100)
pL,PDS(50;50)
pL,PDS(100;100)
pL,PDS(100;50)
[3] [2] [1]
[6] [5] [4]
[8] [7]
0%IEC
IES2
IES1
IES0
120%
80%
100%
50%
pL,PDS(100;100)
pL,RPDS(100;100)
33
Thefollowingtablessummarizetherelative losses intheoperatingpointsdefinedinthestandardIEC61800-9-2.ThetablesshowsthelossesforthesuggestedcombinationsofBSRandActiveCube410.
Power drive system energy efficiency
Pn Size - Rating - Speed IES RPDS IES1 Operating points
kW Class Point 1 1 2 3 4 5 6 7 8
0,37 BSR 71B E 15 IES2 79,7% 32,1% 29,2% 26,1% 24,1% 19,4% 15,2% 14,9% 13,1%
0,55 BSR71C E 15 IES2 61,4% 29,1% 27,7% 24,1% 19,7% 14,7% 15,1% 11,2% 10,1%
0,55 BSR 80B E 15 IES2 61,4% 31,1% 28,5% 25,9% 23,0% 18,9% 16,7% 14,7% 12,5%
0,75 BSR80C E 15 IES2 51,7% 24,6% 22,0% 19,9% 16,0% 14,1% 13,1% 10,3% 9,5%
1,1 BSR 90S E 15 IES2 44,0% 21,0% 18,0% 15,2% 14,3% 11,6% 10,3% 8,0% 7,3%
1,5 BSR90L E 15 IES2 39,1% 20,6% 17,4% 15,2% 13,5% 10,2% 9,0% 7,2% 6,2%
2,2 BSR100LA E 15 IES2 34,6% 18,9% 15,9% 15,0% 11,8% 9,1% 8,5% 6,1% 5,5%
3 BSR100LB E 15 IES2 31,6% 16,9% 16,1% 15,1% 10,1% 8,3% 7,6% 5,0% 4,4%
4 BSR 112M E 15 IES2 29,1% 13,9% 11,8% 10,4% 7,5% 6,1% 5,4% 4,7% 3,2%
5,5 BSR 132S E 15 IES2 26,6% 12,9% 11,4% 9,8% 7,4% 5,1% 4,9% 3,5% 2,8%
7,5 BSR132MA E 15 IES2 24,1% 11,4% 10,1% 8,5% 6,8% 4,7% 3,9% 2,6% 2,8%
9,2 BSR 132MB E 15 IES2 - 9,7% 7,8% 7,1% 4,8% 4,1% 3,2% 2,0% 1,9%
0,55 BSR 71B O 15 IES2 61,4% 36,6% 45,0% 48,9% 20,8% 18,4% 16,6% 12,2% 11,4%
0,75 BSR71C O 15 IES2 51,7% 32,4% 30,2% 22,2% 15,4% 12,7% 10,2% 9,6% 9,1%
0,75 BSR80A O 15 IES2 51,7% 36,6% 35,1% 29,1% 20,8% 18,4% 16,6% 12,2% 11,4%
1,1 BSR 80B O 15 IES2 44,0% 32,5% 31,2% 24,8% 16,3% 13,1% 11,1% 9,4% 8,8%
1,5 BSR80C O 15 IES2 39,1% 28,0% 30,0% 25,1% 13,1% 12,0% 10,9% 12,0% 7,0%
2,2 BSR 90S O 15 IES2 34,6% 21,8% 22,0% 22,6% 11,1% 9,3% 9,0% 5,6% 5,0%
3 BSR90L O 15 IES2 31,6% 21,4% 21,5% 20,5% 10,0% 8,5% 8,1% 4,9% 4,6%
4 BSR100LB O 15 IES2 29,1% 18,4% 19,3% 19,6% 9,1% 7,8% 7,1% 4,6% 4,1%
5,5 BSR 112M O 15 IES2 26,6% 17,1% 18,3% 17,9% 8,1% 7,0% 6,2% 4,0% 3,6%
7,5 BSR 132S O 15 IES2 24,1% 15,3% 17,0% 16,4% 7,1% 6,3% 5,3% 3,4% 3,2%
9,2 BSR132MA O 15 IES2 - 13,6% 15,7% 14,9% 6,1% 5,5% 4,4% 2,9% 2,7%
11 BSR 132MB O 15 IES2 21,7% 11,9% 14,3% 13,4% 5,1% 4,7% 3,4% 2,4% 2,3%
1,1 BSR 71B O 30 IES2 44,0% 26,1% 23,1% 19,4% 17,5% 11,1% 10,1% 8,1% 6,9%
1,5 BSR71C O 30 IES2 39,1% 24,9% 21,4% 20,1% 17,4% 10,1% 9,8% 8,4% 6,1%
1,5 BSR80A O 30 IES2 39,1% 25,3% 22,1% 19,3% 16,2% 11,5% 9,3% 7,5% 5,5%
2,2 BSR 80B O 30 IES2 34,6% 21,8% 18,7% 15,9% 13,5% 9,6% 7,9% 5,7% 4,4%
3 BSR80C O 30 IES2 31,6% 17,6% 16,8% 12,7% 11,0% 7,5% 12,2% 4,8% 11,7%
4 BSR 90S O 30 IES2 29,1% 15,4% 13,2% 9,7% 9,7% 6,5% 5,1% 4,1% 3,1%
5,5 BSR90L O 30 IES2 26,6% 14,6% 13,1% 12,7% 8,3% 5,6% 5,0% 3,3% 2,7%
7,5 BSR100LB O 30 IES2 24,1% 14,8% 11,7% 9,8% 8,9% 5,7% 7,7% 3,4% 6,6%
11 BSR 112M O 30 IES2 21,7% 10,2% 8,4% 5,7% 6,3% 4,1% 3,1% 3,1% 3,0%
15 BSR 132S O 30 IES2 19,9% 11,0% 7,5% 4,9% 6,0% 4,0% 3,0% 2,8% 2,9%
18,5 BSR132MA O 30 IES2 18,9% 9,0% 6,5% 4,7% 5,9% 3,9% 2,7% 2,6% 2,4%
34
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