A REGAL-BELOIT COMPANY

Unipak 2
CACA/CACW

High Voltage A C
Induction Motors

Motors for the Long Run!

Unipak2

One of India's most modern motor

factories, incorporating extensive CAD
facilities with over 50 years' experience
in the design and application of
induction motors, enables MARATHON
Electric to offer the benefits of proven
solutions :

MARATHON Electric has over

2500 MW installed world-wide.

IP 55 enclosure protection as
standard on enclosed machines.

Upto 4000 KW range capability.

Factory fixed Air Gap.

All speeds available.

Compliance with National and

International Standards.

Highest available efficiency - rapid

pay-back.
High Power Factor - Low Power
Cost.
20 years' expected design life at
1000 starts per year
Resivac VPI Insulation System for
total winding reliability.
Highest quality - lowest
maintenance costs.
Low Noise Level - Better
performance than IS:12065.
Low vibration level - conforms to
IS:12075.

Built to type N requirements.

Upto 11 kV, 50 or 60 Hz. supply.
Low Starting Current design
available.
Variable speed drive compatibility.
Horizontal mounting.
Rolling or Plain Bearings.
Environmentally friendly motors
to meet all drives.
Type e version available on
request.
Slipring version available.

Standards and Specifications

Compliance with the International
Standard IEC 34 ensures that motors
also meet the requirements of other
aligned National Standards
including :
INDIA
BELGIUM
FRANCE
GERMANY
ITALY
NETHERLANDS
NORWAY
SWEDEN
SWITZERLAND
UNITED
KINGDOM

Compliance with other specifications

and standards such as NEMA-MG1
and API 541 can be offered, and
further major user specifications can
be met on request. Please check with
our sales department of the address
given on the back of this publication
for more detailed information.
Many company and project
specifications use IEC 34.1 as a basis
or reference and thus compliance may
be asured.

KW

IS:325
NBN 7 : 1963
NF C 51-111
VDE 05301/1.66
CEI 2-3, N. 355
NEN 3173
NEN 41.69
SEN 2601 01
SEV 3009
B5 4999 & 5000

POWER OUTPUT
4000
3600
3200
2800
2400
2000
1600
1200
800
400

VOLTAGE

3300 6600 3300 6600 3300 6600 3300 6600 3300 6600 3300 6600

POLES
(REV/MIN)

2(3000)

4(1500)

met, together with machines for

variable speed drive systems. Proven
designs exist for most driven equipment
needs (e.g. compressors, pumps, fans,
crushers and mills).

Electrical Supply
All National and International supply
voltages and frequencies are catered
for by the Unipak range.

Insulation

Air-cooled CACA (TEAAC) IC 0161,

Water-cooled CACW (TEWAC) IC
OA1W7, Open Ventilated (OVDP) IC
01, and NEMA II enclosures are
available as standard options.

Unipack Class F Resivac Vacuum and

Pressure Impregnation Insulation
systems comply with IEC 85. After
impregnation the stator windings are
subjected to the voltage tests specified
in IEC 34.1. All machines are subject
to loss tangent tests.

Horizontal Foot Mounting to IM 1001

& Vertical Mounting to IM 3011.

Degree of Protection by
Enclosure

Dimensions

IP 55 as standard for totally enclosed

water or air cooled machines.
Protection and enclosure types are as
recommended by IEC 34-5 & IS:4691.

Shaft and fixing dimensions are in

accordance with the requirements of
IEC 72 and 72A together with
BS 4999 part 141 & IS:8223.

Frame Sizes

8(750)

10(600)

12(500)

NOTE : FOR 11 KV , PLEASE REFER TO WORKS

Cooling Methods

Mounting Arrangements

6(1000)

Cooling Method

Shaft centre heights from 400 to 710

mm are covered.

Methods of cooling are as

recommended by IEC 34-6 (complete
system) & IS:6362.

Speeds

Ventilation

All fixed speed requirements can be

The designs employ radial ducted

ventilation using shaft mounted steel

fans to circulate the internal cooling
air. CACA (TEAAC) motors are fitted
as standard with high efficiency, unidirectional low noise level, shaft
mounted steel fans.

Noise Level
Particular attention has been given to
all sources of noise generation and
Unipak standard designs meet the most
stringent modern requirements, (i.e.
typically 85 dB (A) at 1 metre).

Vibration
Unipak motors comply with the
requirements of API 541, and
IS:12075. Rotors are dynamically
balanced prior to assembly in two
planes. Vibration is then checked on
test before and after overspeed tests
to prove stability.

Efficiency
Typically, full load efficiencies greater
than 96% are achieved as standard
ensuring low operating costs.

Starting Current
Standard designs are within BS 4999
Part 112 design D limits. Lower starting
current designs can be tailored to suit
specific supply system limitations where
required.

Construction
Rotor Cage Windings
Rotor bars are designed and
manufactured to maintain a tight fit
throughout the slot length and depth,
and are connected to the end-rings by
means of a specially developed oneshot brazing process ensuring total
reliability throughout the life of the
motor. Cage designs are optimised to
ensure a minimum starting capability
of 1000 starts per year over a 20-year
period.

Frames
Unipak Motor frames are of box
configuration, manufactured from cast
iron or Fabricated Steel, thus ensuring
an extremely robust and rigid support
structure. The top of the frame has a
rectangular opening to allow fitment
of the air/air or air/water heat
exchanger, or alternative ventilation
arrangements.
Stator and Rotor Cores
Stator core packs are built on
expanding mondrels using packets of
insualted, low-loss laminated electrical
steel, interspersed with I-beam spacer
sections which form radial cooling
ducts. Cores are hydraulically
compressed between substantial steel
end-plates and the entire assembly is
secured by sequentially welding
langitudinal steel core-bars to the back
of the laminations and the end-plates
to maintain the pressure. The core bars
extend beyond the end plates to form
rigid anchorages for bracing of the
end windings.
Rotor cores are built against a
compression plate utilising packets of
insulated laminations in a similar
manner to the stator cores. These are
then shrunk onto the shaft assembly
and retained by circumferential keys.
4

Stator Coils
All Unipak stator Coils are
manufactured from annealed copper
strip, insulated with mica-paper tape.
Loops are formed withthe appropriate
number of turns, and the coil is then
pulled into the required shape in a
forming machine. Layers of mica tape
insulation are then added, followed
by the application of corona shield or
semi-conducting tape as appropriate
to the supply voltage.
The coils are inserted into their slots in
the stator core pack and fixed firmly
in position with slot wedges.
Endwindings are securely braced, thus
ensuring the prevention of movement
during starting and service.
High voltage tests are carried out both
before and after connection, and again
after impregnation in order to check
insulation integrity. On completion of
the winding process, resistances and
impedances are checked for balance
and design conformly.

End Winding Bracing

The end winding bracing system is
designed to match the rotor capability
of a minimum 1000 starts per year for
20 years and to withstand the stresses
involved in 180 degrees out-of-phase
reswitching.
Winding Impregnation
The RESIVAC Vacuum Pressure
Impregnation System (VPI) is employed
on all Unipak Motors. This system
ensures global impregnation of the
entire wound stator core assembly
using a specially developed solventless
epoxy resin. The process guarantees
that all air and moisture is extracted
under vacuum from the winding before
pressure then forces resin into every
void within the assembly.
Curring of the resin is carried out whilst
constantly rotating the assembly in on
oven to ensure even distribution. The
entire impregnation operation is
microprocessor controlled and data
logged to ensure total reliability of the
windings during ser vice life.

FRAME POCKET

UNIPAK 2 CACA TYPICAL SECTION

CACW Cooler

TERMINAL RAIL
TERMINALS

N.D.E. ENDBRACKET

C.A.C.A. COOLER
GASKET

GASKET

GLAND PLATE

COVER PLATE

TYPICAL TERMINAL ASSEMBLY

INLET MESH

FAN INLET EYE

SATOR FRAME

FAN COWL

BEARING
INNER CAP
D.E. ENDBRACKET

EXTERNAL FAN

COPPER ENDRING

COPPER BAR

FLINGER

LAMINATIONS
COVER PLATE
HEATER
CORE END-PLATE

INTERNAL FAN

GASKET
FAN BAFFLE

TERMINAL BOX

LAMINATIONS

FRAME BASE
ROTOR SHAFT
GASKET
SHAFT SEAL

COVER PLATE

SPREADING CHAMBER

CORE-BAR

STATOR COREPACK PRIOR TO WINDING

HEATER LOCATION AT EACH END OF FRAME

Curring of the resin is carried out

whilst constantly rotating the assembly
in on oven to ensure even distribution.
The entire impregnation operation is
microprocessor controlled and data
logged to ensure total reliability of the
windings during ser vice life.

Shaft
Shafts are manufactured from carbon
manganese steel bar material of grade
150M19 to BS970. Welded-on
longitudinal arms are utilised. Standard
motors have a single parallel shaft
extension. Where appropriate, motors
may utilise forged shafts and integral
half-couplings.

Bearings and Lubrication

Plain white metal or rolling element
endshield-mounted bearings are
available to suit appropriate motor
application and speed.
Plain bearings incorporating specially
developed multiple labyrinth floating
oil and air-seals ensure that dynamic
changes of motor internal pressure do
not adversely affect the lubrication
system and allow IP55 degree of
protection as standard. Centre flange
bearings are used on larger machines
giving considerable benefits of
improved rotor dynamic performance
and overall motor efficiency. Plain
bearings are insulated at the spherical
seating on both bearings, enabling
simple testing of insulation integrity.
In operation, an earth connection at
the drive-end avoids any build-up of
voltage. Either rolling element or plain
bearings are available on slower speed
machines and are selected for
minimum maintenance and to avoid
the need for external lubrication
systems.

Impregnation Vessel

Bearing arrangement

Terminations
Fault rated elastomeric connectors
(with or without mechanical protection),
steel weatherproof boxes, phase
insulated or fault rated phase
segregated terminal boxes, and
terminal boxes including provision of,
or for surge diverters, current
transfarmers etc. can be provided
where appropriate. Winding neutral
terminations may be concealed behind
a cover or brought out to an external
chamber to allow for the fitting of
current transformers etc. where
required. Terminal boxes can be
provided on either side of the machine,
and are able to accept cable entry
from any of 4x90 degree positions.

Paint System
Surfaces are degreased, then blast
cleaned to ISO 8501 and ISO 8503,
which deline surface cleanliness and
roughness. Surfaces are then primed
using a modified synthetic resin red
oxide primer to a dry film.

Phase segregated Terminal Box

Line
Voltage

0,2-0, 5s greater than 1.0s

wavefront
wavefront

kV

kV

p.u.*

kV

p.u.*

3.3

13.47

18.86

A single finish coat of two pack Epoxy

Point is applied.

4.16

17.00

23.77

6.6

17.00

32.33

Auxiliaries

11.0

26.94

49.39

5.5

Anti-condensation heaters meet type

LN requirements as standard and are
easily withdrawable for maintenance
without dismantling the motor. Bearing
temperature, viberation monitoring,
cooling system performance is
available as required.

13.2

32.33

59.27

5.5

13.8

33.80

61.96

5.5

Impulse withstand levels for standard

Resivac stator windings.
(*p.u.=per unit; 1 p.u. is equal to the
peak value of the phase voltage.)

Total Quality
We are manufacturing complete range
of HT motors with quality assurance
plan endorsed by major consultants
of our country. Also over principals
of Rugby had laid down stringent
acceptance norms in each stage of
production for the above motors. All
imput materials are critically tested inhouse as per National/International
standards to ensure error free end
product.
Full range of Unipak motors are routine
tested at rated voltage and power in
our test plant. Type testing can be
done upto 4000 KW, 11KV, 4 pole.

CAPACITANCE

Our customers are welcome to be

associated during stage inspection or
final inspection during manufacture
of every stage.

DRY
VACUUM

WINDING
MMERSED

FIRST STAGE OF
PRESSURE CYCLE

STABILITY AND
CONTINUATION OF
PRESSURE CYCLE

IN RESIN
TIMES

HOURS

Graph of winding capacitance to earth during the impregnation process

showing the shart increase when preasure is applied.

10

NEUTRAL POINT
TERMINAL BOX

AD3

BEAMA CEGB
TERMINAL BOX

AD2

PHASE SEG.
TERMINAL BOX

AD1

HC

260 160 100 120

320 130 130 140

850 1000 530 203 1042 1270 906 888 1022 857 719
850 1250 530 203 1042 1270 906 888 1022 857 719

500U1250

56OU1120 950 1120 600 230 1180 1515 1050 1030 1166 1000 890

85

85

85

NOTE : FOR GA DRAWING ABOVE 560 MM CENTER HEIGHT, PLEASE REFER TO WORKS.

260 160 100 120

260 150 110 100

260 150 110 100

240 150 155

240 150

65

65

500U1000

949 784 646

80
200 120 120

200 120

750 1120 500 162 908 1125 833 815

949 784 646

894 729 590

894 729 590

838 673 533

838 673 533

450U1120

900 500 162 908 1125 833 815

800 475 156 826 1010 778 760

900 355 125 710 894 722 704

710 355 125 710 894 722 704

750

450U900

BC

686 1000 475 156 826 1010 778 760

BB

400U1000

BA

686

AE

TB

400U800

AD AD1 AD2 AD3

BC

610

AC

BB
BA

355U900

AB

STEEL W/P
TERMINAL BOX

610

AA

ED
KWAY

61

355U710

AA

AD

A
AB

AC

FRAME

AA

AE

WHEN 4 X 90 ADAPTOR
FITTD ADD 178mm TO
DIMS AD, AD1 OR AD2 FOR BOX WIDTH

176

4 HOLS DIA K DIA

52

HA

Unipak 2 Overall Dimensions

ED

200 180 560

210 194 500

210 194 500

210 174 450

210 174 450

170 155 400

170 155 400

140 119 355

140 119 355

BA

TB

670

670

2150 42 3550 1415 1075

1898 35 3445 1220 930

1898 35 3225 1220 930

1711 35 3189 1230 830

1711 35 2989 1150 830

1484 35 2869 1035 750

1484 35 2760 1035 750

1311 28 2390 875

1311 28 2282 859

HC

L DIMENSION IS WITH
STANDARD FAN FITTED

45

45

45

45

45

40

40

38

38

HA

2 POLE SLEEVE BEARINGS

GENERAL DIMENSIONS

AIR INLET

11

NEUTRAL POINT
TERMINAL BOX

AD3

52

BEAMA CEGB
TERMINAL BOX

AD2

PHASE SEG.
TERMINAL BOX

AD1

176

HA

HC

750

750 1120 315 162 908 1125 833 815

850 1000 335 203 1042 1270 906 888 1022 857 719
850 1250 335 203 1042 1270 906 888 1022 857 719
950 1120 355 230 1180 1515 1050 1030 1166 1000 890

450U900
450U1120
500U1000
500U1250
560U1120

949 784 646

949 784 646

WHEN 4 X 90 ADAPTOR
FITTD ADD 178mm TO
DIMS AD, AD1 OR AD2 FOR BOX WIDTH

BB

80

BC

85

100

95

95

320 130 130 160

260 160 100 130

260 160 100 130

260 150 110 120

260 150 110 120

240 150 155 100

240 150

200 120 120

200 120

BA

TB

BB
BA

NOTE : FOR GA DRAWING ABOVE 560 MM CENTER HEIGHT, PLEASE REFER TO WORKS.

900 315 162 908 1125 833 815

894 729 591

894 729 591

838 673 533

838 673 533

686 1000 280 156 826 1010 778 760

800 280 156 826 1010 778 760

900 254 125 710 894 722 704

710 254 125 710 894 722 704

400U1000

AE

686

AD1 AD2 AD3

400U800

AD

610

AC

355U900

AB

STEEL W/P
TERMINAL BOX

610

AA

AA

ED
E WAY

355U710

A
AB

AD

AA

AC

FRAME

4 HOLES K DIA

AE

Unipak 2 Overall Dimensions

ED

240 220 560

250 216 500

250 216 500

210 176 450

210 176 450

210 194 400

210 194 400

170 155 355

170 155 355

45

45

45

45

45

40

40

38

38

HA

TB

830

750

750

670

670

L DIMENSION IS WITH
STANDARD FAN FITTED

2150 42 3340 1210 1075

1898 35 2940 1065 930

1898 35 2760 1065 930

1711 35 2685 1045 830

1711 35 2485 965

1484 35 2307 880

1484 35 2198 880

1331 28 2123 804

1311 28 2016 788

HC

4 TO 12 POLE ROLLING
ELEMENT BEARINGS
GENERAL DIMENSIONS

X
AIR INLET

Vertical UNIPACK2 Motor

A REGAL-BELOIT COMPANY

Marathon Electric Motors (India) Ltd. Registered & Head Office: 58, Taratala Road, Kolkata - 700024. LT Motor & Fan Factory, Paharpur Works, 58,
Taratala Road, Kolkata - 700024, Fax: 2469 5369 / 8530, Phone : 09903900801. Large LT Motor & HT Motor Factory, AEI Works 1, Taratala Road,
Kolkata- 700024. Marathon Regional Offices: New Delhi: 708, Eros Building, 56, Nehru Place; Tel: 011 4160 7123, 09313290402. Chandigarh:
Chamber No. 8a, 2 Floor, Sco No. 2441-42, Sector 22-C; Tel: 09316102451. Mumbai:114 Navneelam, R.G. Thadani Marg, Worli; Tel: 022 3265
9844, 09322645753, Fax: 022 3040 1555. Pune: 41/14, Office Club Swaroop Complex Karve Road; Tel: 020 2546 3978, 09371025388. Ahmedabad:
415 / Platinum Plaza, Nr. Pushkar Tower, Judge-bunglow-bodakdev Road; Tel: 079 2560 2297, 09327048567. Nagpur: 1 Floor, Block A, Thapar
Enclave, Plot No. 148, Ramdaspeth; Tel: 0712 2526 220, 09373283527. Raipur: 1 Floor, 141, Sundernagar, Near Adarsh Chowk; Tel: 0771 2210
240. 09329128913. Chennai : Door No. 9, Flat No. 7, 1 Floor, Thiru. Vi. Ka. Road, Royapettah, (opp, Sathyam Theatre), Tel: 044 4351 0152,
09382102392, Fax: 044 4351 0153. Secunderabad: Cabin No. 47, 303, Swapnalok Complex, 92, S. D. Road; Tel: 040 2781 2724, 09391340619.
Bangalore : C1-101, White House, 15 Cross, 6 Main R. T. Nagar; Tel: 080 2655 8729, 09341279429. Bhubaneswar : C/o. Plot No. 16-b, Engineers
Colony, Old Station Bazar; Tel: 0674 231 3744, 09338212907. Jamsbedpur: C/o. Mr. D. P. Ghosh, House No. 7, Bidyasagar Path, Uliyan, Kadma;
Tel: 0 93346 12014. Marathon Electric India Pvt. Ltd., Sec.-11 Model Town, Faridabad - 121006 (INDIA), Tel: 0129 2286421/2265340; Fax : 01292284855, email : [email protected] GEMI Regional Offices : Ahmedbad : 406, Vedant Complex, 7, Kalpana Colony, Off. C.G. Road,
Navrangpura, Ahmedabad-380009, Tel: 079-26561819, 9825611502. Fax: 079-26560452. Chennai : 6 Arcot Road, Vadapalani, Chennai - 600092,
Tel: 044-42136697, 42333353, 9840429331, Fax: 044-42082322. Jaipur : C/o Flat No. 104, Block A, Rama Heritage Apartments, Central Spine,
Vidhyadhar Nagar, Jaipur-302 023. Ph: 9982655661. Kolkata : 58, Taratala Road, Kolkata - 700024; Tel: 91 033 24695560/61, Fax: 033
24695369/8530. Mumbai : B-908/909, Sagar Tech Plaza, Andheri - Kurla Road, Saki Naka, Andheri (East), Mumbai - 400072, Tel: 022-28523106,
9833756269, Fax: 022-28528938. Pune : C/o: 8, Sethu Apartments, Right Bhusari Colony, Paud Road, Kothrud, Pune-411038, Tel: 020-65224846,
9960604846. Bangalore : Tel:9342299995. Hyderabad : Tel:9393002665. Delhi : Flat No. 516-518, 5th Floor, Antriksh Bhawan, 22 K.G. Marg New
Delhi -01 Tel: 9873184209.

MEMI/CAT/UNIPAK2/1108/02 Replaces RMPP 005 0196/2008

Specialized custom built motors Specialists in short cycle deliveries