EMZ High-Voltage Motors & Large Drives Special Cement Edition
→ EMZ Products → Spare Motors & Replicas → Repair & Service → Engineering
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EMZ Cement special
Preface
Dipl.-Ing. Benedikt Mathiaszyk
Managing Director Large Drive & Projects
Dear Ladies and Gentlemen,We are pleased to present our product series of high-
voltage motors and large drives to you with this spe-
cial catalogue which is exclusively compiled for the
cement industry.
Thanks to our years of experience with custom-
ers from the cement industry, we are familiar with
the comprehensive requirements of internationally-
operative OEMs and know the practical needs of the
operators in the plants.
EMZ stand for products and services of excellent
quality, quick delivery, and competitive prices. With
the use of modern manufacturing processes and high
quality materials, we guarantee maximum reliability
and operational safety for our high-voltage motors and
large drives.
Our qualified sales team take your individual require-
ments into account and provide personal, expert
advice to help you choose the right high-voltage drives
and complete drive-systems.
Ask us; we will be delighted to assist you with your
enquiries and look forward to working with you.
EMZ‘s premises in Recklinghausen
cover 20,000 m2, whereby 5,000 m2
alone are for warehousing, a further
1,800 m2 for workshops and 800 m2
used for office space.
01 Production 03 Repair & Service
02 Spare Motors & Replicas 04 Engineering
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EMZ supplies high-voltage motors and large drives for
all kinds of applications in the cement industry. The
motors are manufactured in accordance with IEC and
EN 60034 standards. They comply with all interna-
tionally applicable regulations.
On request, the EMZ motors can be manufactured
according to NEMA MG2 standards and IEEE testing
regulations.
The high quality standards of the
EMZ products are guaranteed by
the certification of our quality as-
surance system in accordance
with EN ISO 9001 standards.
Available from stockWe stock up squirrel-cage motors up to 6,000 kW, as
well as slipring motors up to 5,000 kW. Therefore, our
well sorted warehouse enables prompt delivery in
case of emergency or damage.
Applications for EMZ motors → Ball mills
→ Vertical roller mills
→ Roller presses
→ Crusher
→ Kiln drives
→ Fans
→ Conveyor belt
Applications
Ball mill Vertical roller mill
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EMZ Cement special
AKR & ASR motors are surface cooled according to
IC411 (IEC 60034-6). A compact design and great reli-
ability characterise our motors.
AKR series Squirrel-cage motorsASR series Slipring motors
The motors are available in the IEC frame sizes 315,
355, 400, 450, 500, and 560mm and can be manufac-
tured with a maximum output of 2,000 kW.
EMZ AKR & ASR motors are suitable for heavy and
extreme conditions. They are available in standard
design for operation with fixed speed but also for speed-
regulated use with frequency converters.
01 ProductionAKR & ASR Motors
Squirrel-cage motors AKR 355-04 for conveyor drive Slipring motor ASR 450-06 for coal mill drive
Design→ Compact cast-iron housing
→ Two-circuit cooling system for internal and
external cooling
→ Reliable bearing design with SKF/FAG
rolling bearings
→ VPI insulation system in thermal class F
→ Use of copper rotors for difficult start-up
conditions for AKR motors
→ Designed for operation with fixed speed
and for VFD application
Power range→ Performance 150 to 2,000 kW
→ Voltage 2,000 to 13,800 V
→ Frequency 50 and 60 Hz
→ Number of poles 2 to 12 pole
→ Protection type IP 55
→ Cooling type IC 411
→ Mounting IM B3 and IM V1
Surface cooled three-phase motors AKR & ASR series
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01 Production 03 Repair & Service
02 Spare Motors & Replicas 04 Engineering
AK Motors
AKL 710-06, 2,500 kW, 6,000 V, 990 rpm for fan application AKL 560-06,1,200 kW, VFD for heat exchanger fan
Based on the basic module of a welded stator hous-
ing, the squirrel-cage motors of the AK series can be
adapted perfectly to suit the individual requirements
of each application. They are available for use with
fixed speed and for VFD applications.
Designs(type designation according to IEC 60034-5/6):
AKD series
Protection type IP23/W24/R54 | Cooling type IC01/31
AKL series
Protection type IP55 | Cooling type IC611/616
AKW series
Protection type IP55 | Cooling type IC81W
The rotor cage construction of the basic design is made
of rectangle copper bars which are hard-soldered with
the grooved short circuit rings. For special applications
with difficult start-up and operating conditions, we can
use double-cage rotors.
Power range→ Performance 150 to 15,000 kW
→ Voltage 2,000 to 13,800 V
→ Frequency 50 and 60 Hz
→ Number of poles 2 to 24 pole
→ Protection type IP 23/W24/R54/55
→ Cooling type IC 01/31/611/81W
→ Mounting IM B3 und IM V1/V10
Modular three-phase squirrel-cage motors AK series
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EMZ Cement special
EMZ slipring motors are used in the cement produc-
tion when a high starting torque and/or a low starting
current is/are required. Identical to the modular cage-
rotor series, the slipring motors of the AS series are
developed onto the basic module of the welded stator-
housing construction.
The following designs are available(descriptions according to IEC 60034-5/6):
ASD series
Protection type IP23/W24/R54 | Cooling type IC01/31
ASL series
Protection type IP55 | Cooling type IC611/616
ASW series
Protection type IP55 | Cooling type IC81W
Massive shaft design for second shaft end By using massive shafts, all slipring rotors can be con-
structed with a second shaft end designed for twice
the nominal torque. The rotor winding is executed in
thermal class F and manufactured as a corded two-
layer winding. Further, the individual rotor bars are
hard-soldered after insertion and secured with a stur-
dy bandage against the occurring centrifugal forces.
BearingsWe can guarantee a long service life and low main-
tenance costs by using high-quality rolling bearings
manufactured by SKF and FAG, and sleeve bearings
which are manufactured by Renk.
Raw mill fan
ASL 560-06 1,400 kW
Ball mill drive
ASL 630-06 4,200 kW
Modular three-phase slipring motors AS series
01 ProductionAS Motors
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02 Spare Motors & Replicas 04 Engineering
Sliprings and carbon brushesThe standard version slipring motors are available with
permanently-mounted carbon brushes or, on request,
with a short-circuit and brush-lifting device. Essential
criteria for low wear-and-tear parameters are the use
of high-quality carbon brushes and brush holders, as
well as the load-optimised design of the carbon brush-
es. Taking all of this into account, our ASL slipring mo-
tors ensure a maximum operating availability.
Power range→ Performance 150 to 15,000 kW
→ Voltage 2,000 to 13,800 V
→ Frequency 50 and 60 Hz
→ Number of poles 4 to 24 pole
→ Protection type IP 23/W24/R54/55
→ Cooling type IC 01/31/611/81W
→ Mounting IM B3 and IM V1/V10
Ball mill drives
4,800 kW and 4,200 kW
Slipring motor ASL 630-06
3,500 kW, 11,000 V, 992 rpm
AccessoriesAll EMZ high-voltage motors can be equipped with a
wide range of accessories:
→ Pt100 resistance thermometers for winding
and bearing
→ SPM detectors and vibration monitoring 4-20mA
→ Bentley Nevada vibration monitoring
→ Anti-condensation heating elements
→ Contact thermometer
→ Star point terminal box
→ Current transformers for differential protection
→ Tachometer generators
→ Slipring room lighting
→ Pressure switch for filter monitoring
Modular three-phase slipring motors AS series
AS Motors
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EMZ Cement special
Liquid starter DFA 2000 for ball mill
ASD 710-12, 2,000 kW, 10,000 V, 495 rpm
1,500 kW; 6,000 V Soft starter.
Oil-cooled drum startersThe oil-cooled drum starter consists of individual cast
iron elements which are manufactured according to
the required resistance parameters and mounted in an
oil reservoir.
Liquid startersThe liquid starter is a con-
tinuously-adjustable resistor
with a three-phase electrode
system which is moved in an
electrolyte. Through the con-
centration of the electrolyte,
the starter resistance can be changed and the starter
optimally adjusted to the respective load conditions.
Medium-voltage soft startersOur electronic soft starters allow a controlled reduc-
tion of the starting current and the start-up torque
when starting squirrel-cage motors.
Power range→ Performance max. 16,000 kW
→ Nominal voltage 1,500 to 15,000 V
Technical Data→ Vacuum contactor
→ Vacuum bypass contactor
→ Motor-protection relay (MSR)
→ Multifunction display (DMA)
→ Current limiting
→ Adjustable torque and current characteristics
→ Boost start (high starting torque)
01 ProductionStarters
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01 Production 03 Repair & Service
02 Spare Motors & Replicas 04 Engineering
ApplicationsVariable speed drives with asynchronous motors and
frequency converters are used in many different ap-
plications with various operating conditions. You can
find a lot of these drives operating fans and kilns in ce-
ment factories. Increasingly, these frequency convert-
ers are also used for high performance vertical roller
mills. A process-conditioned adjustment of the grind-
ing table rotation speed can increase the production
capacity and optimise the grist quality.
Optimised drive solutions We offer practicable drive solutions that are custom-
ised to fit your requirements and processes. On the
basis of our experience and expertise we are able to
compile selected components for the ideal drive solu-
tion that will meet all your expectations.
Frequency converter during the final inspection Frequency converter 1.2 MW
Medium-voltage frequency convertersMedium-voltage frequency converters are used in ap-
plications where powerful speed control is required
and where low-voltage frequency converters have
reached their economic and technological limits. With
these, the rotation speed and the torque of asynchro-
nous and synchronous machines are optimally adapt-
ed to suit the actual requirements; energy consump-
tion is optimised and the CO² emissions reduced.
Technical designs Direct converters which can be put “direct to drive”
without a matching transformer are available for volt-
ages up to 6,600 V and a max. current of 285 A. The
quality of the output voltage as almost perfectly sinu-
soidal enables the use of existing motors without re-
ducing the nominal output for constant speed opera-
tion with 50 Hz.
Frequency Converters
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EMZ Cement special
New replaceable spare motors without any reconstructionMany main drives in cement factories have been in use
for decades in severe application conditions, operating
as drives for cement mills, crushers, and fans. These
drives are often designs with base frames in the frame
size D5/IM7211. The stator housing and the pedestal
bearing housings are mounted on a separate steel
base frame. With these designs, the use of modern re-
placeable spare motors with the frame size B3/IM1001
is often dependent on expensive and time-consuming
modifications executed on the foundations.
With our know-how, EMZ can offer you replaceable
spare motors specialised for these drives. Our motors
can be fitted on-site on the existing base frame. We
take into account that the base frame will be loaded
at the identical positions compared with the origi-
nal motor. Further, we consider the matching for the
stator- and rotor connection.
EMZ offers the perfect solution→ Accurate recording of the actual state of
the application in your facility
→ Comparison with current requirements
→ Development of a suitable concept together
with the operator
→ Detailed co-ordination of construction and
accessories
→ Routine and type testing according to
IEC/EN 60034-1
→ Installation, commissioning, and training
Ball mill 1,700 kW, 10,000 V, 495 rpm Ball mill 2,400 kW, 10,000 V, 495 rpm
02 Spare Motors & Replicas Spare Motors
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01 Production 03 Repair & Service
02 Spare Motors & Replicas 04 Engineering
Based on our experience and the numerous success-
fully-completed projects, we guarantee an all-around
service when you require replaceable spare motors.
Our specialists come to your plant and gather all rele-
vant data that we need in order to prepare a quotation
for a 100 % interchangeable spare motor.
Advantages for the operator→ 1:1 mechanical interchangeable
→ Structural modifications of the foundation are
not necessary
→ Identical position of the stator- and rotor
connection
→ Identical cable entries for stator and rotor cables
→ Identical electric data for stator and rotor winding
→ Application of the existing rotor starter
→ Application of the existing coupling half on
the motor side
→ Production safety due to the modern VPI insulation
system thermal class F, utilisation according to
thermal class B (85K)
→ Improvement of efficiency due to the use of
loss-optimised electrical sheet steels
→ The brushes equipping is optimised according
to the plant conditions
→ Short reconstruction period due to guaranteed
interchangeability
Ball mill 3,600 kW, 3,300 V, 595 rpm Vertical roller mill 5,500 kW, 3,300 V, 990 rpm
100% interchangeable replicas for existing motors
Replicas
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EMZ Cement special
Case study 1 Case study 2Our customer in Germany required a spare motor
which will be used as an interchangeable spare motor
for 3 identical cement mill drives. The supplied motor
with the design B20/IM1101 can be mounted and con-
nected without any further modifications on the exist-
ing base frame on-site.
In this case, the installation conditions of the 3,500 kW
motor were extremely confined. The spare motor
ASL 630-06 had to be 100% mechanical and electri-
cal interchangeable. This means that the dimensions
and position of the insulators in the stator and rotor
terminal box needed to be identical. As desired by the
customer, an additional set of Rogowski coils for the
differential protection monitoring was mounted.
Ball mill – original motor
1,700 kW, 10,000 V, 990 rpm
Type test – spare motor
EMZ ASD 630-06, 1,700 kW, 10,000 V, 990 rpm
Slipring motor EMZ ASL630-6 during installation
3,500 kW, 11,000 V, 992 rpm
Ball mill drive brand Converteam in UK
3,500 kW, 11,000 V, 992 rpm
02 Spare Motors & Replicas Case Studies
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01 Production 03 Repair & Service
02 Spare Motors & Replicas 04 Engineering
Ball mill drive in UK, year of construction 1967
1,700 kW, 11,000 V, 500 rpm
Coal mill drive in Malaysia
Siemens type 1LS1 454-6, 350 kW
Case study 3 Case study 4Our customer from England operates very special syn-
chronous slipring motors in 2 production facilities. We
manufactured a customised spare motor. This asyn-
chronous slipring motor has the special design D9/
IM7201 and can be mounted on the existing base frame.
Since the base frames of the original motors in both
production facilities are not identical, the spare motor
can be adapted to fit the respective installation condi-
tions by using adapter plates.
Our customer is using a slipring motor from Siemens,
type 1LS1 454-6, which is no longer available now-
adays. We supplied a 100 % interchangeable spare
motor that is a customised construction from EMZ
which was manufactured with a second shaft end for
the auxiliary drive. For the operator it was possible to
install the motor without making any further adjust-
ments.
Replacement s pare m otor d uring a cceptance t est
1,700 kW, 11,000 V, 494 rpm
Spare motor EMZ AKS 450-06
350 kW, 6,000 V, 990 rpm
Case Studies
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EMZ Cement special
Repair & rewindingMany high-voltage motors in cement factories have
been in use for decades in severe application condi-
tions. Older motors especially are often designed with
protection type IP23 or IPR44, as open-through-ven-
tilated motors where the stator and rotor winding is
cooled directly by inducing the surrounding dust ex-
posed air.
The contamination of the windings in combination with
high humidity increases the partial discharge, which
accelerates the ageing process of the winding insula-
tion. By executing a complete renewal of the stator
and rotor windings to thermal class F, the active parts
will be put into new condition, which guarantees the
operator a high level of reliability.
Our services→ Evaluation of the actual condition of installed
motors on the basis of
→ Machine vibrations
→ Measuring of insulation resistance
→ Bearing analysis
→ Thermography measuring
→ Complete mechanical overhauling
→ Stator and rotor winding renewal to thermal class F
→ Disassembly, installation, laser-supported
alignment, and commissioning
→ Recording of the starting conditions of slipring
motors with a 4-channel recorder
→ Commissioning and set-up of rotor starters
regarding the operating conditions
Disassembly of 1,700 kW ball mill drive Installation of 1,700 kW SR Motor after
stator & rotor rewinding
03 Repair & ServiceRepairs
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Advantages for the operatorCompletely overhauled and on demand winding rene-
wed motors offer many advantages for the operator:
→ High level of reliability and an optimal availability
→ Stator & rotor winding renewal in thermal class F
→ Better insulation strength due to the use of
modern insulation material
→ Thermal reserve capacity due to the increase
from thermal class B to thermal class F
→ Checking, repair, or replacement of
existing bearings
→ Optional retrofit of modern monitoring systems
→ Optimised use of the carbon brush equipping
with regards to the operating environments
→ Reduction of carbon brush wear-and-tear
Mechanical repairs and reconstructionsWe offer you the possibility to modify and reconstruct
your machines.
→ Change of protection type
→ Installation of vibration sensors
→ Installation of tacho-generators and rotation
direction sensors
→ Installation of voltage surge arrestors and
counters
→ Installation of thermal sensors for any
measuring points
→ Change of cooling type due to reconstruction
of the heat exchanger
→ Change of direction of rotation
Rotor rewinding slipring motor 1,700 kW
with new slipring body construction
Stator and rotor rewinding
BBC motor 4,500 kW, 10,000 V, 495 rpm
Rewinding
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EMZ Cement special
The EMZ service concept includes the complete main-
tenance of your motors. We take care of all works,
from installation to commissioning, maintenance, and
repair.
The EMZ service concept→ Delivery & installation
→ Maintenance & inspection
→ Repair
→ Breakdown analysis & repairing of faults
→ Spare parts supply
→ On-site measurements (insulation value,
thermography)
→ Vibration measurements & analysis
→ Starter set-up and optimisation
→ Trainings
EASA MembershipEMZ is an accredited member of EASA since 1997.
Owing to our membership, EMZ is able to rely on 2,000
partners worldwide. Thus, we can provide professional
support worldwide at short notice.
Siemens Solution Partner
As a certified Siemens Solution Partner Automation
Drives for the fields “large drives“ and “motors simolog“
we offer our customers an overall service for the re-
spective Siemens products.
Commissioning ASL 500-04
1,800 kW, 1485 rpm
Installation and commissioning AKD 630-06
5,300 kW, 6,600 V, 1490 rpm
The EMZ service concept
03 Repair & ServiceService Concept
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01 Production 03 Repair & Service
02 Spare Motors & Replicas 04 Engineering
All measuring and examinations are executed accord-
ing to EN 60034 standards with our own testing sta-
tion. Our qualified staff is available to assist you on-site
for any machine diagnostics.
Range of our EMZ testing department→ Complete no-load testing according to EN 60034
standards up to 6,000 kW
→ Recording of no-load and short-circuit
characteristics
→ Vibration analysis
→ Ascertainment of the polarity index (PI-index)
→ Rotor bar-break testing for three-phase
squirrel-cage motors
→ Hotspot measurement for magnetic core
→ Noise measurement
→ Operational balancing
→ Ascertainment of the magnetic centre and
the axial play
→ Smooth running measurements of
commutators and sliprings
→ Measurements of brush contact pressure
→ Checking of air flow rate and velocity of flow
in the cooling circuit
Complete type testOn request it is possible to execute complete type tests
for all motor types. Depending on the torque of the mo-
tor, the load measurement is realised with a direct load
of the motor or alternatively with a partial load measure-
ment according to EN 61986 standards.
EMZ AKR motors during routine test Mill drive ASL 630-06 at the EMZ testing station
4,200 kW, 4,160 V, 60 Hz, 1190 rpm
Optimal quality assurance due to EMZ testing department
Quality Management & Acceptance Tests
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EMZ Cement special
04 EngineeringSolutions
Customised solutions in the cement industryThanks to our years of project experience in the cement
industry, we can offer you comprehensive technical ad-
vice and assistance for your drive solutions. From de-
velopment to construction, manufacture to operation,
we guarantee a standard of quality for our products and
service that will convince you of our expertise.
EMZ Engineering→ Project handling incl. installation, commissioning,
and training
→ 100% interchangeable replicas for existing motors
→ Customised constructions for special
drive solutions
→ Reduction of carbon brush wear-out
Fault analysis & Repairing of faults→ Examination of the plant on-site
→ Problem analysis
→ Supply of spare parts
→ Fault fixing & repair
Sleeve bearing reconstruction for hydrostaticsBy using a rotation-speed independent hydrostatic unit,
the rotor shaft in the bearing shell is lifted with a pres-
sure of 80 to 150 bar, thus ensuring a safe and wear-
and-tear-free operation at very low rotational speeds
and when starting up. The hydrostatic units can be con-
nected independently from a central oil lubrication unit
directly to the oil reservoir of the sleeve bearing.
Discussion with the plant’s engineers Inspection of the v ertical r oller m ill d rive on -site
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02 Spare Motors & Replicas 04 Engineering
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Other EMZ catalogues:→ EMZ Reference Catalogue
→ EMZ Image Brochure
→ EMZ Low-Voltage Motors’ Catalogue
→ EMZ High-Voltage Motors’ Catalogue
Catalogue requesteMail: [email protected]
Would you be interested in further EMZ catalogues?
If you are, please visit our website at www.emz.de.
All catalogues and references are available to download
in our “Download” section or as a printed edition.
Do you wish further information?
Please contact our specialists.
We are looking forward to hearing from you.
Phone: +49 2361 -6909 -0
You can find further information and complete contact
details for the respective product group on our website:
www.emz.de
Please visit our website and convince yourself of our va-
rious references.
EMZ cataloguesEMZ contact person
Contact & references
Ball mill Vertical roller mill
Contact & Catalogues
5,000 kWavailable from stock
Up to
EMZ Product Portfolio: Electric motors (for high and low voltage) → Three-phase squirrel cage motors up to 15,000 kW
→ Three-phase slipring induction motors up to 15,000 kW
→ DC motors up to 2,500 kW
Gear motors → Helical-gear motors
→ Worm-gear motors
→ Bevel-gear motors
Transformers (for high and low voltage) → Oil-filled transformers up to 20,000 kVA
→ Cast-resin transformers up to 6,000 kVA
→ Dry-filled transformers up to 1,000 kVA
Power electronics → Frequency converters
→ Inverters
Service → Maintenace & Repairs
→ Diagnosis
→ Testing department
Contact: Germany:
EMZ Elektro-Maschinen-Zentrale GmbH
Richardstrasse 70
45661 Recklinghausen, Germany
Phone: +49 2361 -6909 -0
Fax: +49 2361 -6909 -99
Web www.emz.de
eMail [email protected]
Switzerland:
EMZ Unitec AG
[email protected] | www.emz.ch
Phone: +41 52 633 42 42
France:
EMZ France Sarl
[email protected] | www.emz.fr
Phone: +33 (3) 89 62 79 09
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