IEC 60349 2 Edition 3 0 2010 10 INTERNATIONAL STANDARD NORME INTERNATIONALE Electric traction – Rotating electrical machines for rail and road vehicles – Part 2 Electronic converter fed alternating cu[.]
Exchange of information
The motor and converter designers shall collaborate to produce all the technical information necessary to ensure that the combined unit will meet the requirements of this part of
To fulfil this requirement, the motor designer shall provide the converter designer with all the information necessary to fully evaluate the interaction between the motor and the converter
The converter designer must supply the motor designer with detailed characteristics, including the converter's line-to-line output voltage—highlighting repetitive voltage peaks—current, fundamental frequency, harmonics, and power across the entire application range This data should cover operation at both the maximum and minimum contact-system voltage values to ensure optimal motor performance.
The documents recording this exchange of information shall form an integral part of the specification of the motor and of the converter
NOTE 1 For more information refer to IEC 61287-1, 5.3.1.1
NOTE 2 The length of cable run between motor and converter and the effect on peak voltages seen at the motor terminals should be considered
NOTE 3 For information about wave fronts and the impact to the motor see IEC 60034-17.
Specified characteristics
Motor specifications should generally include characteristic curves as outlined in the relevant clauses of this standard These "specified characteristics" curves must be plotted according to the designed operating limits of each variable Unless otherwise agreed upon by the user and manufacturer, the curves should represent machine performance at the nominal supply system voltage defined in Annex D Additionally, these characteristics must be provided to the user prior to placing the motor order.
Declared characteristics
Declared characteristics are derived from the results of type tests carried out in accordance with 8.2.1 and shall meet the requirements of 8.2.2
Unless otherwise agreed, the declared specifications of motors that are electromagnetically identical to previously manufactured units for the same user or application will match those of the existing motors In these cases, compliance with the specified characteristics is verified through routine testing only.
Efficiency characteristics
Efficiency characteristics must consider losses caused by harmonics in the converter supply Additionally, power used for excitation of synchronous motors should be included in the loss calculations unless it is accounted for separately, such as an auxiliary load, in which case this exclusion must be clearly stated in the efficiency characteristics.
Traction motor characteristics
The specified and declared characteristics of a traction motor must include converter-fed variable frequency data, illustrating motor line-to-line voltage, current, frequency, mean torque, and efficiency across the entire speed range For asynchronous motors, slip characteristics should be shown, while synchronous motors must display excitation current Voltage and current curves are required to present the root-mean-square values of the fundamental components, with current curves also showing the total root-mean-square value Additionally, for motors operating in braking mode, corresponding characteristics must depict torque input and electrical output as functions of motor speed.
NOTE 1 Subclause 5.1 refers to the need for the exchange of information between the designers of the motor and of the converter
As an alternative to motor torque and speed, the characteristics can be expressed as tractive effort at the rail and vehicle speed In this case, it is essential to specify the gear ratio, wheel diameter, and transmission losses When using conventional values for transmission losses, they must comply with established standards to ensure accuracy and consistency.
NOTE 2 Clause 1 refers to the need to consider the effect on parallel-fed motors of differing wheel diameters and of weight transfer between axles.
Auxiliary motor characteristics
The specified and declared characteristics of auxiliary motors must reflect the converter-fed parameters, including motor line-to-line voltage, current, speed, and mean torque as functions of motor output across all operating frequencies For motors with continuously variable frequency operation, the characteristics should be plotted only at the maximum and minimum frequencies, ensuring comprehensive performance data throughout the motor's application range.
Asynchronous motors are characterized by slip, while synchronous motors are identified by their excitation current Voltage curves must display the root-mean-square (RMS) value of the fundamental component, and current curves should present both the RMS value of the fundamental component and the total RMS value These characteristics should consider additional losses caused by supply harmonics, and the efficiency at the guaranteed rating must be clearly stated.
Alternatively, the characteristics may be plotted as a function of speed
NOTE Subclause 5.1 refers to the need for the exchange of information between the designers of the motor and of the converter
Nameplate
All motors covered by this part of IEC 60349 shall carry a nameplate including at least the following information: a) Manufacturer's name b) Motor type designation c) Motor serial number d) Year of manufacture
Every motor must have a serial number punched on both the stator and rotor, ensuring traceability and identification Additionally, motors designed for unidirectional rotation are required to display an arrow indicating the correct direction of rotation, enhancing safety and proper operation.
NOTE The motor serial number and rotation arrow should be easily readable when the motor is installed in the vehicle.
Terminal and lead marking
Terminal and lead markings shall be in accordance with IEC 60034-8 unless otherwise agreed
Test categories
General
There are three categories of tests:
NOTE See Clause 1 on duplication of tests.
Type tests
Type tests are conducted to verify the ratings, characteristics, and performance of new motor designs These tests must be performed on one motor from each new design, typically selected from the first ten units produced If there is a change in the manufacturing location or method, additional guidelines outlined in section 7.1.2.4 should be followed.
Before testing begins, the manufacturer must provide the user with a detailed test specification outlining the required tests to ensure compliance with the standard After completing the type tests, the manufacturer is responsible for delivering a comprehensive test report to the user.
7.1.2.2 Type tests on converter supply
For optimal testing, each motor should be powered by its dedicated converter, ideally using the exact converter intended for service Alternatively, a supply that closely mimics the vehicle converter's waveform and harmonic characteristics can be used to ensure accurate type test results.
When multiple motors are powered in parallel from a single converter, type testing must be performed on a single motor using a supply that closely matches the vehicle converter's waveform and harmonic characteristics.
If requested by the user, the manufacturer must demonstrate the similarity between the test and service supplies and explain the potential impact of any differences on the motor's performance.
Unless otherwise agreed, the type test shall be repeated if the electrical output characteristics of the converter are changed
7.1.2.3 Type tests on sinusoidal supply
This test is to provide a reference for the characteristics of a machine
The test shall include a temperature rise test at a rating agreed between the manufacturer and the system responsible
Manufacturers have discretion over voltage, frequency, torque, ventilation, and test duration, but the test must last at least one hour and be conducted under conditions that do not overstress the machine beyond normal service levels.
The test parameters shall be maintained for any subsequent test on that design of machine
The temperature rise measurements shall be carried out as detailed in 8.1
Subject to agreement, and to the results of both the type test on sinusoidal supply
According to section 7.1.2.3, if routine tests meet the established tolerances from previous motors, a full type test is not necessary provided the manufacturer supplies a full type test report for a motor with the same electromagnetic design at the same or higher rating This requirement also applies to repeat orders and cases involving changes in the manufacturing location or method.
Routine tests
Routine tests ensure that a motor is correctly assembled, capable of withstanding the necessary dielectric tests, and functions properly both mechanically and electrically.
Routine tests outlined in Clause 9 are typically performed on all motors; however, prior to placing an order, the user and manufacturer can mutually agree to implement an alternative testing procedure.
In cases where motors are produced in large quantities under strict quality assurance procedures, routine testing of every motor may be reduced Instead, full tests might be conducted on a randomly selected proportion of motors from each production order However, all motors must undergo the dielectric tests specified in section 9.5 to ensure compliance and safety.
Investigation tests
Investigation tests are optional special tests conducted to gather additional information about motors These tests are performed only when there is a prior agreement between the user and the manufacturer before placing the motor order The outcomes of investigation tests do not affect the acceptance of the motor unless explicitly agreed upon by both parties.
Summary of tests
Table 1 lists the tests required for compliance with this part of IEC 60349
Test category Tempera- ture rise
Short-time thermal test/heat run
Over- speed Dielectric Vibration Noise
All motors, including those type tested, shall be routine tested a Optional tests, subject to agreement between user and manufacturer
Temperature-rise tests
General
The tests shall be carried out at the guaranteed ratings of the motor
The rated mechanical output of a motor can be determined either by direct or indirect measurement at the motor shaft, or by supplying the motor with the specified voltage, current, and frequency indicated in the declared characteristics to achieve the rated mechanical output without direct measurement.
In continuous rating tests, the time required to reach a steady temperature can be reduced by starting the test with an increased load or decreased ventilation However, it is essential to maintain the rated conditions for at least 2 hours or until it is confirmed through appropriate methods that steady temperatures have been achieved.
NOTE Steady temperature is defined as a change in temperature of less than 2 K during the final hour of the test.
Ventilation during rating tests
Motors must be tested with ventilation configured as it would be during actual service, including all components that influence temperature rise, such as ducting and filters considered part of the vehicle, or under conditions that provide an equivalent setup.
When cooling is achieved through forced ventilation, it is essential to measure both the static pressure and the airflow at the motor inlet This allows for the creation of a table that accurately represents the relationship between these two parameters, ensuring effective monitoring and optimization of the cooling system.
Typically, cooling generated by the vehicle's movement is not provided; however, in special cases like totally enclosed traction motors where effective cooling is crucial, it may be implemented with mutual agreement between the user and manufacturer.
Measurement of temperature
The temperature shall be measured in accordance with Annex A.
Judgement of results
The temperature rises of the windings and slip rings at the “commencement of cooling” as defined in A.4 shall not exceed the values given in Table 2.
Limits of temperature rise
The different thermal classes of insulation systems are defined in IEC 60085
Table 2 specifies the permissible temperature rise limits above the cooling air temperature, measured on the test bed, for windings and other components insulated with materials from the thermal classes currently used in motor construction relevant to this standard.
If different parts of the same machine have different thermal classes of insulation, the temperature-rise limit of each part shall be that of its individual thermal class
Table 2 – Limits of temperature rise for continuous and other ratings
Thermal class of insulation system
Rotating field windings of synchronous motors
Cage rotors and damping windings Electrical thermometer The temperature rise shall not be sufficient to endanger any windings or other parts
For totally enclosed motors, the limits above are increased by 10 K
When motors are directly or indirectly exposed to heat from an engine or other sources, users and manufacturers may agree to adopt temperature rise limits lower than those specified in Table 2 to ensure optimal performance and longevity.
Short-time overload test
If short-time overload ratings are specified, they shall be verified by one or more tests carried out as follows
At the conclusion of the previous temperature-rise test, the initial temperature rise listed in Table 3 can be determined by extending the cooling curve of the critical winding until the predicted temperature rise, extrapolated for no more than 5 minutes beyond the last reading, reaches the "start" value in Table 3 The specified overload must then be applied at this predicted time under normal ventilation conditions and maintained for the designated duration, after which the test is concluded and the temperature rise is measured according to section 8.1.3.
If the measured temperature rise is within 20 K of the final value specified in Table 3, adjustments to either the rated current or the duration can be made through calculation to achieve an estimated value that meets the required criteria.
Table 3 temperature rise If the measured temperature rise differs from the Table 3 value by more than 20 K, the test shall be repeated with amended values of either current or duration
Table 3 – Temperature rises for short-time overload ratings
Thermal class of insulation system Part
Rotating field windings of synchronous motors At end of test 130 K 155 K 180 K 200 K 220 K 250 K
NOTE 1 For totally enclosed motors, the temperature rises given above are increased by 10 K
NOTE 2 An alternative method of obtaining the starting temperature rise may be employed if agreed between manufacturer and user
NOTE 3 If agreed between user and manufacturer, the temperatures of other motor parts (e.g the rotor cage, damping windings, bearings, etc.) may be measured.
Characteristic tests and tolerances
General
To demonstrate compliance with specified characteristics, tests must measure both the electrical input to the motor and its mechanical output The mechanical output can be determined either through direct measurement or by calculating it from the output of a driven electrical machine with a known efficiency.
Alternatively, and if agreed between user and manufacturer, either the output or input of the motor being tested may be derived by summation of the losses
Load tests must be performed with the motor operating near its reference temperature, and results should be adjusted if temperature corrections are significant Adequate test data should be collected to accurately plot the motor's declared performance characteristics.
The electrical input to the converter shall be measured by an agreed method, but it shall not influence the acceptance of the motor
The electrical input to the motor can be adjusted from the specified characteristics through mutual agreement between the motor and converter manufacturers This modification is allowed provided that the temperature rise of all motor and converter components remains within their specified limits during operation at the guaranteed rating Additionally, the motor losses must stay within the tolerance defined in section 8.2.2 to ensure optimal performance and reliability.
The specified excitation current of a synchronous motor may be similarly modified
The tests shall be carried out in only one direction of rotation
The instruments measuring the complex waveforms of the motor input must accurately indicate current, voltage, and power values to ensure compliance with specified tolerances.
Tolerances
The declared torque at any electrical input within the specified range between the maximum torque and 90% of the maximum speed must be at least 95% of the specified value, ensuring consistent performance and reliability.
The motor losses at the guaranteed rating shall not exceed the value derived from the specified characteristic by more than 15 %
The temperature rise from the sinusoidal supply type test (see 7.1.2.3) where applicable, shall not vary by more than ±8 % or ±10 K, whichever is the highest, from the original type test
The torque shown in the declared characteristics at the guaranteed rating shall be not less than the specified value
The current at the guaranteed rating shall not exceed the specified value
The current to produce the specified starting torque shall not exceed the value specified to the converter manufacturer in accordance with 5.1.
Overspeed test
An overspeed test must be conducted on all converter-fed motors to ensure their reliability During this test, motors are operated at 1.2 times their maximum working speed, as specified in section 3.16, for a duration of 2 minutes while hot This procedure verifies the motor's performance and safety under conditions exceeding normal operating speeds.
Rotors can be tested either before assembly or within the stator, provided they are heated to a temperature similar to that reached during the guaranteed rating test In both testing methods, measurements must be taken before and after the test to assess any rotor distortion.
Vibration tests
A quantitative vibration measurement is to be taken as a type test Where a machine incorporates an integral gearbox, the gear assembly must be removed or gearbox replaced by a supporting end shield
For vibration measurement during type testing, the machine can be placed directly on the test board without any mounting equipment The vibration velocity must not exceed 3.5 mm/s at machine speeds up to 3,600 rev/min For speeds above 3,600 rev/min, the vibration velocity should remain below 5.25 mm/s to ensure optimal performance and compliance with standards.
If the machine design has no fixed bearing the longitudinal velocity of vibration could be excluded
For additional information see IEC 60034-14.
Measurements on variable speed machines shall be taken at a number of speeds covering the whole working range
Vibration velocities exceeding the limiting values can occur due to resonances in the test mountings; however, these should be disregarded if they do not align with a specific working speed and the overall velocity level across the speed range remains within acceptable limits.
Should such a resonance occur at a discrete working speed, the test shall be repeated with an alternative mounting arrangement
NOTE The effect of externally generated vibrations on the machine is outside the scope of this document
Reference should be made to IEC 61373
General
Routine tests shall be carried out in one direction of rotation using a sinusoidal supply at power frequency or at a frequency used in service
The use of a waveform different from sinusoidal must be agreed between the manufacturer and the user
The frequencies used for various tests, such as no-load and locked rotor tests, may differ but must remain consistent once established Test point values should be averaged from tests on four motors, including the type-tested machine To minimize temperature variation effects, all tests must be conducted in the same sequence across all motors Efficiency measurements and braking mode tests are not required.
To ensure consistency within a series, the sinusoidal temperature rise test (refer to section 7.1.2.3) can be conducted at regular or random intervals, based on an agreement between the user and manufacturer The test tolerances are specified in section 8.2.2.
Short-time heating run
This test is only applicable to wound rotor machines
With the exception of motors that have undergone the sinusoidal type test, (see 7.1.2.3 and
9.1) each motor shall be run for a short time under conditions which produce a stator winding temperature of at least 150 °C at the end of the test
Attainment of the temperature shall be verified by measurements on the first two motors tested
If the conditions are altered, the verification shall be repeated Once attainment of the temperature has been verified on two motors, no further temperature measurements are required.
Characteristic tests and tolerances
Asynchronous motors
Asynchronous motors must be tested under two specific conditions, including a no-load test at a voltage designed to generate the maximum magnetic flux within the motor This test should be conducted at any speed between 10% and 100% of the rated speed specified in the motor's declared characteristics.
The current shall not vary from the declared value established in accordance with 9.1 by more than ±10 % b) With a locked rotor at a voltage giving approximately the guaranteed rating current
This voltage shall be established on the first motor to be tested and shall be used for all subsequent tests
The current shall not vary from the declared value established in accordance with 9.1 by more than ±5 %.
Synchronous motors
Synchronous motors must be tested by operating them as generators, excited to generate an open-circuit voltage that corresponds to the maximum magnetic flux at any point on the declared characteristic curve.
The excitation current shall not vary from the declared value established in accordance with
9.1 by more than ±15 % b) Driven on short circuit with the excitation adjusted to give the guaranteed rating current
The excitation current shall not vary from the declared value established in accordance with
Overspeed tests
Overspeed routine tests shall normally be carried out only on wound rotor motors, but it may be agreed to extend them to cage-type motors or omit them altogether
Motors undergoing an overspeed test must operate for 2 minutes at 1.2 times their maximum working speed when hot, as defined in section 3.16 After this test, they are required to successfully pass the dielectric tests outlined in section 9.5.
When performing routine overspeed tests, it is important to take precautions, such as reducing the test speed to no less than the maximum working speed, to prevent damage to rolling bearings caused by high-speed operation without load.
Dielectric tests
Testing is typically conducted using alternating current (a.c.) with a near sinusoidal waveform and a frequency ranging from 25 Hz to 100 Hz However, direct current (d.c.) testing can be used if mutually agreed upon by the user and manufacturer prior to placing an order.
The test voltage must be applied sequentially between the windings of each circuit and the frame, while the windings of all other circuits remain connected to the frame This full voltage is applied exclusively to new motors with all components installed, simulating normal operating conditions.
The test shall be carried out with the motor hot immediately after completion of the routine tests specified in the preceding clauses
The test voltage must be the highest value specified in Table 4 for the selected test method and should be applied gradually, starting at no more than one-third of the final voltage Once the final voltage is reached, it must be maintained for 60 seconds to ensure accurate testing results.
1 All windings other than group 2
2 Excitation windings of synchronous motors
10 U e a.c or 17 U e d.c., with a minimum of 1 500 V a.c or 2 550 V d.c and a maximum of 3 500 V a.c or 5 950 V d.c
U dc is the highest mean voltage to earth which can be applied to the d.c link when the contact system is at its maximum voltage and the machine is motoring
The maximum repetitive peak voltage to earth, denoted as \$U_{rp}\$, represents the highest voltage that can be repeatedly applied to a machine winding when the contact system operates at its maximum voltage and the machine is in motoring mode This repetitive peak voltage is crucial for ensuring the machine's insulation withstands operational stresses, as defined in section 3.14.
U rpb is the maximum repetitive peak voltage to earth which can appear on the winding when the machine is braking
U e is the maximum mean value of the excitation voltage
If neither the d.c link nor the motor windings are normally earth referenced, then U dc , U rp and
U e shall be taken as the highest voltages to earth that can appear on their respective circuits, should any point on them become connected to earth
A lower value for repeated tests shall be agreed between user and manufacturer of the motor
Remark: The value used to test the converter (see IEC 61287-1) shall be lower or equal to the value used to test the motor
NOTE This subclause defines requirements for the serial test Please consider IEC 60034-18-41 for the qualification of a winding system.
Vibration tests (imbalance)
Each machine must be inspected for vibrations caused by imbalance to ensure smooth operation Typically, it is sufficient to verify that the machine runs smoothly when mounted on the test bed and powered at the supply frequency For machines with an integral gearbox installed during routine testing, the vibration check can also be performed with the gearbox fitted.
In applications where machine vibration is considered critical, if agreed between user and manufacturer, the tests detailed in 8.4 can be carried out on each machine
A.1 Temperature of the motor parts
The temperature of insulated windings shall be measured by the resistance method, that of permanently short-circuited windings and that of slip rings by the electrical thermometer method
No correction shall be made to the measured temperature rises if the temperature of the cooling air is between 10 °C and 40 °C during the test
If the cooling air temperature is outside these limits during a type test, a correction to the measured temperature rises may be agreed between user and manufacturer
Before conducting a short-time test, it is essential to verify that the winding temperatures are within 4 K of the cooling air temperature using a thermometer or resistance measurements When calculating the winding temperature rise, any initial temperature difference up to 4 K must be adjusted by subtracting it if the winding is hotter or adding it if the winding is cooler.
In this method, the temperature rise of a winding is determined by its increase in resistance during the test
For copper windings, the temperature rise at the end of a test is determined by the following formula: temperature rise = t 2 – t a = R
(235 + t 1 ) – (235 + t a ) where: t 1 is the initial temperature, of the winding in degrees Celsius;
R 1 is the resistance of the winding at temperature t 1 ; t 2 is the temperature, of the winding at the end of the test in degrees Celsius;
R 2 is the resistance of the winding at the end of the test; t a is the temperature of the cooling air at the end of the test in degrees Celsius
NOTE For materials other than copper, the value 235 in the above formula should be replaced with the reciprocal of the temperature coefficient of resistance at 0 °C for the material
In this method, the temperature is determined by means of electrical thermometers applied to the hottest accessible spots of the relevant parts immediately after the motor is stopped
A.2 Temperature of the cooling air
For totally enclosed motors, the cooling air temperature shall be measured by not less than four thermometers distributed around the motor and spaced between 1 m and 2 m from them
The temperature of the cooling air must be measured at its entry point to the motor, and if there are multiple entry points, the temperature should be averaged across all measurement locations to ensure accurate assessment.
Thermometers must be shielded from radiated heat and drafts to accurately measure the true temperature of the air entering and surrounding the motor To ensure precise readings, all necessary measures should be implemented to minimize temperature fluctuations in the cooling air.
The temperature of the cooling air at the end of a test is determined by averaging measurements taken at approximately 15-minute intervals during the last hour of a continuous rating test or throughout the entire duration of a short-time test.
The initial cold resistance measurement should be performed using the same instruments as those used for subsequent hot measurements, though it is not necessary to repeat this measurement at the start of each test The winding temperatures must be recorded as their surface temperature using a thermometer during the resistance measurement, ensuring that this temperature does not differ from the ambient air temperature by more than 4 K.
The hot resistance of the motor winding should be measured promptly after stopping the motor at the end of the test This measurement can be performed using the voltmeter and ammeter method (volt-ampere method), a bridge, or other suitable techniques It is essential to use the same measurement method consistently for all readings on a given winding, including the initial cold resistance measurement.
When using the voltmeter and ammeter method, the current must be sufficiently high to ensure accurate measurements while not affecting the temperature rise Typically, maintaining the current at no more than 10% of the rated current achieves this balance effectively.
A.4 Stopping of motors and time of “commencement of cooling”
At the end of a test, the motor shall be stopped in as short a time as possible
A preferred braking method involves the motor under test operating without carrying current In this approach, the "commencement of cooling" is defined as the moment when the main circuits are opened just before braking, with any separate ventilation also being turned off at that time.
If the primary method is impracticable, alternative methods where the test motor carries current can be used, provided they quickly stop the motor and maintain a reasonably constant load current during braking The "commencement of cooling" is defined as the moment when the load current decreases to 80% of the test value, at which point ventilation must be turned off.
A.5 Time of the hot resistance measurement and extrapolation of the cooling and heating curves
Resistance measurements of each winding shall commence not later than 45 s after the
“commencement of cooling” and shall be continued for at least 5 min
The time between successive measurements on each winding shall not exceed 20 s during the first 3 min and 30 s thereafter
For large motors that cannot be stopped quickly enough to begin measurements within 45 seconds, special braking arrangements and an extended measurement time of up to 2 minutes must be agreed upon between the user and the manufacturer.
The temperature rise, determined from the readings, will be plotted against time using a logarithmic scale for temperature and a linear scale for time This curve will then be extrapolated to the point of "commencement of cooling" to accurately determine the temperature rise at the end of the test.
Conventional values of traction motor transmission losses
If conventional values of traction motor transmission losses are included in the efficiency calculation they shall be in accordance with figure B.1
Figure B.1 – Conventional values of traction motor transmission losses
Curve a represents the loss per stage of reduction for gears with parallel shafts, while curve b illustrates the loss per stage for gears with shafts positioned at right angles Both curves account for suspension or gearbox bearing losses, providing a comprehensive understanding of efficiency variations in different gear configurations.
These conventional losses are intended for use in vehicle performance calculations when more specific data is unavailable They should not be used as criteria for accepting or rejecting machines or gearing.
If noise measurement is required, it must be specified by the user and conducted on a single machine from the order Alternatively, a test record demonstrating compliance with noise requirements on an identical machine, previously constructed and tested according to the methods in this Annex or an earlier edition of IEC 60349, may be accepted Sound pressure level measurement and calculation of sound power level must follow Clauses C.5 to C.6, unless alternative methods in C.1 c) apply Additionally, maximum sound power levels and corrections for pure tones are clearly defined.
Clauses C.7 and C.8 c) When appropriate, one of the methods of precision or engineering grade accuracy, such as the methods of ISO 3741, ISO 3743-1, ISO 3743-2, ISO 3744, ISO 3745, ISO 9614-1 or