New Business Cards are in the Mail

 Meanwhile…

 Bob Nelson
 4800 SW Macadam Ave, Suite 240
 Portland, OR 97201

 Phone 971-544-1683
 E-fax 860-298-3692
 Mobile 503-970-1484
 e-mail bob.nelson@us.abb.com (same)

ABB Automation
 COMPARISON OF IEC AND NEMA STANDARDS
For Large AC Induction Motors

ABB AUTOMATION INC

Bob Nelson
Ray Doran
Ed Keffer
Steve Waite
David Rains

ABB Automation
The Standards
 IEC 60034
 (International Electrotechnical Commission)
– Rotating Electrical Machines

 NEMA MG1
 (National Electrical Manufacturers Association)
– Motors and Generators

ABB Automation
Focus Topics
 Rating / Performance

 Degree of Protection / Enclosure

 Method of Cooling

 Mounting

 Dimensions

 Explosion Protection

ABB Automation
Applicable Standards (IEC)
 IEC
– IEC 60034 Rotating Electrical Machines

1 Rating and Performance

5 Classification of Degrees of Protection
6 Methods of Cooling
7 Classification of Types of Constructions and Mounting
Arrangements

– IEC 60072 Dimension and Output for Rotating Electrical Machines

1 Frame Numbers 56 to 400 and Flange 55 to 1080

2 Frame Numbers 355 to 1000 and Flange 1180 to 2360

ABB Automation
Applicable Standards (NEMA)
 NEMA MG 1
– Section I - General Standard Applying to all Machines

1 Reference Standards and Definitions

4 Dimensions, Tolerances and Mounting
5 Rotating Electrical Machines - Classification of Degree of Protection
Provided by Enclosures for Rotating Machines
6 Methods of Cooling (IC Code)

– Section III - Large Machines

20 Induction Machines

ABB Automation
1 - RATING AND PERFORMANCE
 IEC 60034-1 - Rating and performance

– Site operation conditions

• The altitude shall not exceed 1000 m above sea-level

• The ambient air temperature shall not exceed 40°C
• The ambient air temperature shall not be less than -15°C for any
machine (< 3300 kW, etc)
• The water coolant temperature at inlet to a machine or heat
exchanger shall not exceed +25°C nor be less than +5°C

– Overspeed
• machines shall be design to withstand overspeed 1.2 times the
maximum rated speed / duration of any overspeed test shall be 2 min

ABB Automation
Rating Standards - Comparison of IEC vs. NEMA

CHARACTERISTIC IEC NEMA

Service Factor
General Purpose 1.0 1.15

Power Supply
Max Voltage Variation +/- 5% +/- 10%

Max Frequency Variation +/- 2% +/- 5%

Max Wave Shape Deviation 5% 10%

ABB Automation
Rating Standards - Comparison of IEC vs. NEMA (cont’d)

IEC NEMA
Service Conditions

Cooling Air  40o C  40o C ( 104o F)

Cooling Water  25o C  30o C ( 86o F)

Altitude 1000 m 1000 m (3300 ft)

Momentary Torque Load

Standard operation 160% 175%

ABB Automation
Rating Standards - Comparison of IEC vs. NEMA (cont’d)

IEC NEMA
Overspeed

>1200 RPM 20 % 25%

<1200 RPM 20% 50%

High Potential Test

Primary Windings 2 x Un+1000 V (1500 V min) 2 x Un+1000 V

ABB Automation
Rating Standards - Comparison of IEC vs. NEMA (cont’d)

Temperature Rise By Resistance

Insulation IEC NEMA

Class 1.0 SF 1.15 SF

A 60 60 70
E 75 - -
B 80 80 90
F 100 105 115
H 125 125 -
ABB Automation
Rating Standards - Differences
 Service Factor
– IEC does not recognize the use of service factor

 Efficiency
– Stray load losses
• IEC 0.5% of the input
• NEMA 1.2% of the output (<2500 HP)
» 0.9% of the output (>2500 HP)

ABB Automation
2- DEGREE OF PROTECTION / ENCLOSURE
 IEC 60034-5 Degree of Protection
– International Protection code (IP code)
– The first characteristic numeral indicates the degree of protection against
contact and ingress of foreign bodies
– The second indicates the degree of protection against ingress of water

IP 4 4
Letters
First characteristic numeral
Second characteristic numeral
– When necessary, the degrees of protection for electrical machines may
have the following letters added following the second numeral:
• W = open weather-protected machine (NEMA specifies after IP Code)
• S = machine tested at standstill for harmful ingress of water
• M = machine tested when running for harmful ingress of water
ABB Automation
Degree of Protection / Enclosure (IEC)
 First Characteristic Numeral (Ingress of foreign bodies)

 0 Unprotected machine.
 1 Machine protected against solid bodies greater than 50 mm.
 2 Machine protected against solid bodies greater than 12 mm.
 3 Machine protected against solid bodies greater than 2.5 mm.
 4 Machine protected against solid bodies greater than 1 mm.
 5 Machine protected against dust.
- (Ingress of dust is not prevented entirely, but the dust is unable to enter in such
quantities as to interfere with the satisfactory operation of the machine)

ABB Automation
Degree of Protection / Enclosure (IEC)
 Second Characteristic Numeral (Ingress of Water)

 0 Unprotected machine.
 1 Machine protected against dripping water.
 2 Machine protected against drops of water falling at up to
- 15° from the vertical.
 3 Machine protected against spraying water.
 4 Machine protected against splashing water.
 5 Machine protected against jets of water.
 6 Machine protected against heavy seas.
 7 Machine protected against the effect of immersion
 8 Machine protected against continuous submersion

ABB Automation
Degree of Protection / Enclosure (NEMA)
 NEMA MG 1 Part 5 (NEMA MG 1 1.25-1.27)
 (Most Common)

 OPEN MACHINE (NEMA MG 1-1.25)

 An open machine is one having ventilating openings which permit passage of
external cooling air over and around the windings of the machine. The term
"open machine", when applied to large apparatus without qualification,
designates a machine having no restriction to ventilation other than that
necessitated by mechanical construction.

 Drip-proof Machine (NEMA MG 1-1.25.1) / DP

 A drip-proof machine is an open machine in which the ventilating openings are
so constructed that successful operation is not interfered with when drops of
liquid or solid particles strike or enter the enclosure at any angle from 0 to 15°
downward from the vertical.

ABB Automation
Degree of Protection / Enclosure (NEMA)

 TYPE I (NEMA MG 1-1.25.8.1) / WP I

 A Weather-protected Type I machine is an open machine with its ventilating

passages so constructed as to minimize the entrance of rain, snow and air-
borne particles to the electric parts and having its ventilated openings so
constructed as to prevent the passage of a cylindrical rod 0.75 inch (19.005
mm) in diameter.

ABB Automation
Degree of Protection / Enclosure (NEMA)

 TYPE II (NEMA MG 1-1.25.8.2) / WP II

 A weather-protected Type II machine shall have, in addition to the enclosure

defined for a weather-protected Type I machine, its ventilating passages at
both intake and discharge so arranged that high velocity air and air-borne
particles blown into the machine by storms or high winds can be discharged
without entering the internal ventilating passages leading directly to the
electric parts of the machine itself. The normal path of the ventilating air which
enters the electric parts of the machine shall be so arranged by baffling or
separate housings as to provide at least three abrupt changes in directions,
none of which shall be less than 90°.

ABB Automation
Degree of Protection / Enclosure (NEMA)
 Totally Enclosed Fan-Cooled Machine (NEMA MG 1-1.26.2) /
TEFC
 A totally enclosed fan-cooled machine is a totally enclosed machine which
equipped for exterior cooling by means external of a fan or fans integral with
the machine but external to the enclosing parts.

 Totally Enclosed Water-Air-Cooled Machine (NEMA MG 1-1.26.8)

/ TEWAC
 A totally enclosed water-air-cooled machine is a totally enclosed machine
which is cooled by circulating air which, in turn, is cooled by circulating water.
It is provided with a water-cooled heat exchanger for cooling the internal air
and a fan or fans, integral with the rotor shaft or separate, for circulating the
internal air.

ABB Automation
Degree of Protection / Enclosure (NEMA)

 Totally Enclosed Air-to-Air-Cooled Machine (NEMA MG 1-1.26.9) /

TEAAC

 A totally enclosed air-to-air-cooled machine is a totally enclosed machine

which is cooled by circulating the internal air through a heat exchanger which,
in turn, is cooled by circulating external air. It is provided with an air-to-air heat
exchanger for cooling the internal air and a fan or fans, integral with the rotor
shaft or separate, for circulating the internal air, but external to the enclosing
part or parts for circulating the external air.

ABB Automation
PROTECTION - COMPARISON BETWEEN NEMA AND IEC
 The symbols, definition and test specifications contained
in IEC 34-5, have been incorporated into NEMA standards

 NEMA IEC*
 Drip-proof machine IP12
 Weather protected type I IP23
 Weather protected type II IP24W
 Totally enclosed fan-ventilated IP44
 Totally enclosed fan cooled IP54/55
 Totally enclosed air-air cooled IP54/55

 * Can’t compare. Cooling designation should also be

provided!
ABB Automation
PROTECTION - COMPARISON BETWEEN NEMA AND IEC

 IEC - IP55 (also IC411)

IEC - IPW24 (also IC01)
 NEMA - TEFC NEMA - WPII

ABB Automation
3 - METHOD OF COOLING
 Method of designation is determined by:

– The coolant used (air, water, etc)

– The manner in which the coolant is circulated (fans, etc)

– The drive system which moves the coolant (self, ext pump. etc)

– IEC 60034-6 (Again uses a numeral / letter designation)

– NEMA MG1 Part 6

ABB Automation
Method of Cooling (IEC)
 First Characteristic Numeral (Circuit Arrangement)

 0 Free circulation
 1 Inlet pipe or inlet duct circulated
 2 Outlet pipe or outlet duct circulated
 3 Inlet and outlet pipe or duct circulated
 4 Frame surface cooled
 5 Integral heat exchanger (using surrounding medium)
 6 Machine mounted heat exchanger (using surrounding med)
 7 Integral heat exchanger (using remote medium)
 8 Machine mounted heat exchanger (using remote medium)
 9 Separate heat exchange (using surrounding or remote med)

ABB Automation
Method of Cooling (IEC)
 Second Characteristic Numeral (Method of movement of coolant )

 0 Free circulation
 1 Self-circulation
 2,3,4 - Reserved for future use.
 5 Integral independent component
 6 Machine-mounted independent component
 7 Separate and independent component or coolant system pressure
 8 Relative displacement
 9 All other components

ABB Automation
Method of Cooling (IEC)

 TYPICAL EXAMPLE

 Simplified Designation

 Code letters IC
 Circuit arrangement 8
 Method of movement of primary coolant 1
 Secondary coolant W

 IC81W (TEWAC)

ABB Automation
COOLING - COMPARISON BETWEEN NEMA AND IEC
 The symbols, definition and test specifications contained
in IEC 34-6, have been incorporated into NEMA standards
 NEMA Part 6 IEC*
 Drip-proof machine / WPI / WPII IC01
 Totally enclosed fan cooled IC411
 Totally enclosed air-to-air cooled IC611
 Totally enclosed water-to-air cooled ICW81

 * Can’t compare. Degree of Protection designation should

also be provided!

ABB Automation
COOLING - COMPARISON BETWEEN NEMA AND IEC

 IP54 IC81W IP54 IC611 IPW24 IC01

 TEWAC TEAAC WPII

ABB Automation
COOLING - COMPARISON BETWEEN NEMA AND IEC

 IEC - IC411 (also IP55) IEC - IC01 (also IPW24)

 NEMA - TEFC NEMA - WPII

ABB Automation
4 - MOUNTING ARRANGEMENTS
 The methods of mounting electric machines are governed
by:
– The direction of the driving shaft (horizontal or vertical)
– The method of support (end-shields or pedestal bearings)
– The method of fixing the frame (feet, flange or fixing lugs)
– The mounting surface (floor, baseplate or soleplates)
– The design of the shaft extension (free, flanged or externally
supported).

ABB Automation
Mounting Arrangment (IEC)
 IEC 60034-7
– International Mounting code (IM code)
– The first characteristic numeral indicates the basic construction of the
machine (mounting to foundation, bearing arrangement)
– The second and third numeral indicates more detailed construction
depending on the first numeral
– The fourth indicates amount and shape of shaft extension(s)

IM 1 0 0 1
Letters
First characteristic numeral
Second characteristic numeral
Third characteristic numeral
Fourth characteristic numeral

ABB Automation
Mounting Arrangment (IEC)
 First Characteristic Numeral (Basic Construction)

 1 With feet and end-shields.

 2 With feet and mounting flange, with end-shields.
 3 With mounting flange on end-shields, with end-shields.
 4 With mounting flange on frame, with end-shields.
 5 With bearings, without end-shields
 6 With end-shields and pedestal bearings
 7 With pedestal bearings only, no end-shields
 8 With vertical shaft, provided the machine does not conform
- to items 1 to 4.
 9 With special mounting arrangement.

ABB Automation
Mounting Arrangment (IEC)
 Fourth Characteristic Numeral (Number / shape of shaft
extensions)

 0 No shaft extension
 1 One cylindrical shaft extension
 2 Two cylindrical shaft extensions
 3 One conical shaft extension
 4 Two conical shaft extensions
 5 One flanged shaft extension
 6 Two flanged shaft extensions
 7 Flanged shaft extension at the D-end and cylindrical
- extension at the N-end.
 8-9 With special mounting arrangement.

ABB Automation
Mounting Arrangment (NEMA)
 NEMA MG 1, Part 4

– the letter indicates mounting to foundation

– the numeral indicates location of terminal box
F-1
Letter
Numeral
– standard mountings (floor mounting)

ABB Automation
MOUNTING - COMPARISON BETWEEN NEMA AND IEC
 (2 most common applications)

» NEMA MG 1-4.03 IEC 34-7, Code II (Code I)

 Horizontal / Floor Mounting

» F-1, F-2 IM 1001

 Vertical / Flange Mounting

» VSS/ VHS IM3011 / IM4011

ABB Automation
MOUNTING - COMPARISON BETWEEN NEMA AND IEC

IEC IM3011
NEMA Vertical

 IEC IM1001
 NEMA F-1/F-2

ABB Automation
5 - DIMENSIONS
 IEC 60072 (2) - Dimensions and Output Series...

– Defines Symbols used for mounting dimensions

– Recommendations for Shaft Height (mm)

• Standard: 315, 355, 400, 450, 500, 560, 630, 710, 800, 900, 1000,
1120, 1250,…

 NEMA MG 1 Part 4 - Dimensions, Tolerances, and Mounting

– Defines Symbols used for mounting dimensions

– Dimensions for Shaft Height up to 500 frame (12.5”)
– Dimensions for Footprint up to 449 frame (11”)

ABB Automation
Dimensions (IEC)

ABB Automation
Dimensions (NEMA)

ABB Automation
DIMENSIONS - COMPARISON BETWEEN NEMA AND IEC
 The Symbols for Mounting Dimensions are not the Same
– Example - Shaft Height
• IEC - H
• NEMA - D

 The Frame Size Designations are not the Same

– Example - NEMA 500 frame is not equal to IEC 500 frame

 Beyond NEMA 500 Frame, Manufacturers can use any

dimensions

ABB Automation
6 - MOTORS FOR HAZARDOUS AREAS

 Flammable gases and vapors mixed in certain proportions with air can
form a mixture capable of being ignited.

 To prevent an ignition, and with it an explosion, no sparks, arcs or

dangerous hot surfaces should arise in the dangerous area.
=> Explosion protection for motors and accessories

 The widest application range for explosion protected motors are found
in the Chemical, Oil, and Gas industry.

ABB Automation
 Hazardous Areas (IEC)

 Defined by Zone (probability), Gas

Group, and Temperature Class
Ex nA
Zone 2 /Category 3 EEx nA
 Gas groups (needed only for Ex d (abnormal conditions) Ex e
and Ex i) EEx e
– IIA (e.g. Propane) Ex p
– IIB (e.g. Ethylene) Zone 1 / Category 2 EEx p
(Occasionally) Ex d
– IIC (e.g. Acetylene and
EEx d
Hydrogen)
 Zones Ex e Zone 0
– Zone 0 - continuously EEx e Category 1
– Zone 1 - occasionally Ex p (Continuously)
– Zone 2 - in abnormal conditions EEx p Ex
 Temperature classes d Not
EEx d suitable for
motors
T1 T2 T3 T4 T5 T6
450 C 300 C 200 C 135 C 100 C 85 C
ABB Automation
Hazardous Areas (IEC)

Zone 0 Zone 1 Zone 2

An Area in which an An area in which an An area in which an
explosive atmosphere explosive atmosphere explosive
is present is likely to occur atmosphere is
continuously or for (periodically or unlikely to occur
long periods (>1000 occasionally) under under normal
h/year). normal operation operation and if it
(10…1000 h/year). does it will exist for
a short period only
(<10 h/year).

Not Suitable for Motor EEx eII T1/2/3/(4) Zone 1

Installation EEx p II T1/2/3/4 Ex nA II T1/2/3/4
EEx d II T1/2/3/4

ABB Automation
 Explosion Protection

 What are the protection types based on?

 How are they put into practice?

 Limiting factors

 When is certification needed?

ABB Automation
 Explosion Protection

Earthing and
Creepage equipotential Clearance between
fan and fanhood
Clearance

Clearance between
rotor and stator
Material

Temperature Construction of
rise rotor

ABB Automation
Explosion Protection (IEC)

Type of protection Ex- Principle of protection

Symbol

General - -
requirements

Flameproof EEx d Enclosure (contain explosion)

enclosure

Increased safety EEx e Design (Limit motor temperature at

any time during operation – incl
starting)

Pressurized EEx p Enclosure (Separation of exposure to

enclosure explosive atmosphere)

“Nonsparking” (E)Ex n Design (Limit motor temperature

Non incendive during steady state operation)

ABB Automation
 Explosion Protection - Non Sparking (Exn)
 Protection is based on
– No sparks at rated operation
– No dangerous hot surfaces at rated operation
– (Does NOT includes starting / stall)

 SAME DESIGN ‘PRINCIPLE’ FOR DIV 2 MOTORS

 All accessories must be Ex-certified / factory confirmation.

 Certificate is NOT needed, a factory confirmation is sufficient.

ABB Automation
 Explosion Protection - Increased Safety (Exe)
 Protection is based on
– No sparks at rated operation nor at the start and fault conditions
– No dangerous hot surfaces at rated operation nor at the start and
fault conditions

– NO EQUIVALENT DESIGN IN NEC

 How is the protection put into practice?

– Proper design and temperature limits
– The start up and locked rotor (time tE) shall be taken into
consideration

All accessories must be Ex-certified at least to the same level.

 Certificate IS always needed

ABB Automation
 Explosion Protection - Pressurized (Exp)
 Protection is based on
– An enclosure which is flushed and pressurised by
a protective gas

Pressurization
– Explosive gas mixtures shall be removed before
the motor can start
– Pre-flushing the internal free volume at least 5X
– Overpressure at least 0.5 mbar during operation

 SAME DESIGN ‘PRINCIPLE’ FOR NEC PRESSURIZED

 All accessories must be Ex-certified at least to the same

level. (inside of enclosure)
 Third party certificate is always needed

ABB Automation
Explosion Protection - Flameproof (Exd)
 Protection is based on

– Gas can be ignited within the enclosure but must be contained

– Cannot damage enclosure or be transmitted outside enclosure

How is the protection put into practice?

– Mechanical design - tolerances, clearances, etc

 SAME DESIGN ‘PRINCIPLE’ FOR NEC EXPLOSION-PROOF

 All accessories must be Ex-certified at least to the same level.

 Third party certificate is always needed

ABB Automation
 Explosion Protection - IEC Marking

Ex na II C T3

 Ex - Explosion protected
apparatus
 nA - Type of Protection
 II - Group (other than mines)

 A, B, C - Gas groups

 Temperature Class

T1 T2 T3 T4 T5 T6
450 C 300 C 200 C 135 C 100 C 85 C

ABB Automation
 NEC / CE Code standards (NEC Article 500)

Explosive material
Class I Gases
Class II Dust
Class IIIFibres
Div 2 motor Division 2
in abnormal conditions
Division 1
Incidence of explosive material
Division 1 Occasionally or continuously
Occasionally or
Division 2 In abnormal conditions continuously Tclass Temp. /C
T1 450
T2 300
T2A 280
Gas groups
T2B 260
Class 1 - Groups e.g. Gas
T2C 230
A Acetylen T2D 215
B Hydrogen
Explosion-proof T3 200
C Ethylene
or pressurized T3A 180
D Methane T3B 165
T3C 160
Class 2 - Groups Dust T4 135
E Metal dust T4A 120
F Coal dust T5 100
G Grain dust T6 85

ABB Automation
Hazardous Areas (NEC)

Div 0 Div 1 Div 2

An Area in which an An area in which an An area in which an
explosive explosive atmosphere explosive atmosphere
atmosphere is is likely to occur is unlikely to occur
present continuously periodically under normal
operation
No Design Pressurized Same
Explosion-proof Div 2 motor

None TEFC Same

TEAAC WP-1/2
TEWAC ODP

ABB Automation
 Marking NEC / CEC (NEC Article 505)

(Gases)
Class I Div 2 Group D T2C
Explosive material

Incidence

Gas group

Temperature class

ABB Automation
COMPARISON - PROTECTION AND CLASSIFICATION

Zone Div Ex Design NEC Design IEC NEC

Enclosure Enclosure

Zone 0 Div 0 None None --- ---

Zone 1 Div 1 Exd Explosion-proof > IP44 TEFC

Exp Pressurized TEAAC
Exe TEWAC
TE__
Zone 2 Div 2 (above) (above) > IP44 TEFC
Exn Div 2 motor (totally Open
enclosed)

ABB Automation
COMPARISON (cont’d)
 For IEC, the machine design is similar if not the same as for NEC
(hazardous gases cannot read motor nameplates!)
 It is the method of classification and certification that separates the
two
 The supply of IEC motors in NEC areas (vice-versa) is rarely permitted

 Hazardous area has to be well defined by the responsible engineering

group
 It is never the responsibility of the equipment manufacturer’s to define
the area

ABB Automation
COMPARISON (cont’d)
 DIFFERENCES

– IEC does not allow the use of open-cooled motors (WPII, ODP, etc)
in a hazardous area

– NEC does not have an equivalent to Exe - Increased Safety

 SIMILARITIES

– Design concept is the same

– More to come… Standards Harmonization is in progress???

– (the gases are the same)

ABB Automation
 ABB

 That’s all

 THANK YOU!

ABB Automation