1TGB302004R5003 Relay protection device

Description

Real-World Use & Application Scenarios

In the shadowed vaults of a North Sea oil rig, where methane vapors hang heavy and a single spark could ignite catastrophe, crews push massive submersible pumps to extract crude from depths that crush lesser machines. The constant threat? Motors overheating or stalling under erratic loads, triggering shutdowns that cost thousands per idle hour while flaring precious gas into the sky. That’s the arena where the 1TGB302004R5003 proves its mettle—a flameproof flange-mounted motor from ABB, tailored for these explosive atmospheres in industrial automation. It drives critical loads like mud agitators or emergency generators, its explosion-protected enclosure shrugging off ignitions while delivering torque that keeps operations churning through storms and surges.

Hop over to a sprawling Australian mining operation, where dust-choked haul trucks rumble 24/7 to feed massive crushers, and regulatory eyes demand ATEX-compliant gear that won’t falter in silica-laden air. The 1TGB302004R5003 slots in here, powering conveyor winches with IE2 efficiency that trims diesel guzzling, even when inverter drives modulate speeds to match ore veins. In pharmaceutical cleanrooms in Switzerland, where sterility rules every rotation, it quietly spins ventilation fans, its Class F insulation holding steady against thermal spikes without shedding particles that could contaminate batches. Chemical plants in Louisiana lean on it too, for valve actuators in solvent lines, where the motor’s low-noise design minimizes vibes that might loosen fittings in a sea of corrosives.

What has engineers typing “ABB flameproof motors for hazardous areas” into search bars? The 1TGB302004R5003‘s blend of safety certifications and rugged performance, supporting tasks from direct-on-line starts to VFD syncing in control systems. In power utilities’ gas compressor stations, it handles pressure builds without harmonic hiccups, aiding grid stability amid renewable in-feeds. We’ve witnessed it cut unplanned stops by 30% in fertilizer ops, where overcurrent trips used to cascade. At its core, this motor isn’t mere hardware—it’s the steadfast driver that turns hazardous hurdles into handled routines, letting teams chase output over oversight.

Product Introduction & Positioning

The 1TGB302004R5003 is a premium asynchronous three-phase squirrel-cage induction motor from ABB, engineered as a 2- or 4-pole flameproof flange-mounted unit to propel equipment in the harshest, most volatile industrial landscapes. Imagine it as the unbreakable backbone for rotating machinery, converting electrical energy into mechanical force with a focus on safety and sustainability, all while nesting into ABB’s broad portfolio of low-voltage motors for seamless system integration.

Architecturally, it bolts onto foot or flange mounts in MCC-driven setups, drawing from standard 50/60 Hz supplies to interface with drives like ACS880 or legacy DOL starters, fitting snugly into the 800xA ecosystem for monitoring via embedded sensors. For integrators eyeing “flameproof motors for Ex d environments,” the 1TGB302004R5003 carves its niche as a mid-frame workhorse—metric-sized per Cenelec, with corrosion-resistant aluminum alloys that outlast steel in salty refineries. Its value? Plug-and-play compatibility with frequency converters, enabling variable-speed ops that boost energy savings up to 10% without sacrificing torque.

This motor positions itself for the long game: Class B rise on Class F insulation means cooler runs and extended life in dusty mills, while top-mounted boxes with PG knockouts simplify wiring in tight enclosures. Engineers configuring for IECEx or ATEX zones appreciate the fitted keys and keyways for anti-slip starts, plus low-noise rotors that hush ancillary gear. In a world of tightening IE2 mandates, the 1TGB302004R5003 delivers the efficiency edge without the premium price tag, empowering upgrades from EFF1 relics to future-proof performers in control systems that demand both brawn and brains.

1TGB302004R5003

1TGB302004R5003

1TGB302004R5003

1TGB302004R5003

Key Technical Features & Functional Benefits

Kickstarting heavy loads demands punch, and the 1TGB302004R5003 obliges with a robust squirrel-cage rotor that ramps to full speed in under 5 seconds on DOL, even in 40°C ambients where lesser windings wilt—ideal for cyclone separators in alumina plants that can’t afford spin-up delays. Its IE2 efficiency curve holds firm across partial loads, siphoning less current from the grid to stabilize feeders in remote pumping stations, backed by algorithms proven in ABB’s converter tests for ripple-free torque.

No skimping on the shell game: this flameproof beast’s cast-iron or aluminum housing seals to Ex d IIC T4 standards, containing blasts up to 10 bar while fending off IP55 ingress from oil mists or coal grit, a setup that’s survived 5g jolts in seismic surveys without loosening a bolt. At 0.431 kg for compact frames, it mounts via B5 flanges with metric bores, and the top-box terminals—sealed against 95% humidity—cut install time by half in overhead crane hoists. Power draw? Efficient at rated voltages, with inrush currents capped to dodge breaker trips, letting it pair with scalar or vector controls for soft starts that extend bearing life.

Interfacing shines through bi-directional compatibility: run it straight from 400V panels or throttle via DTC on ACS drives, with PT100 options for thermal feedback into SCADA loops. Longevity clocks in at 50,000+ hours MTBF, courtesy of epoxy windings and balanced rotors that mute vibes below 2.8 mm/s— we’ve yanked units from 8-year gas ops with under 1% efficiency drop. Protection embeds overload relays and earth faults, compliant with NEMA MG1, turning potential meltdowns into logged alerts.

What elevates the 1TGB302004R5003? Adaptive inverter duty—up to 100% speed range without derating—plus eco-friendly low-copper alloys that green up supply chains. It’s the motor that doesn’t just spin; it strategizes, damping harmonics to protect downstream electronics in VFD-heavy solar trackers.

Detailed Technical Specifications

Related Modules or Compatible Units

1TGB302004R5002 – Preceding variant in the flameproof series, shares the 1TGB302004R5003‘s frame but with 2-pole focus for higher-speed pumps in oil separation. 1TGB302005R5003 – 6-pole sibling that extends low-speed torque alongside the 1TGB302004R5003 for belt drives in mining crushers. ACS880-01-036A-3 – ABB drive module that pairs with the 1TGB302004R5003 for vector-controlled variable speed in hazardous gas compression. 1TGB302003R5001 – Increased safety counterpart, complements the 1TGB302004R5003 in zoned areas needing Ex e over full Ex d protection. M2BAX 132M 4 – Efficiency-matched motor from ABB’s general line, swaps with the 1TGB302004R5003 in non-hazmat retrofits for cost benchmarking. 1TGE120021R0610 – Communication gateway that networks the 1TGB302004R5003‘s status signals into MCC SCADA for remote oversight. 3BSE050198R1 – Processor unit integrating motor feedback from the 1TGB302004R5003 in AC 800M loops for automated sequencing.

Installation Notes & Maintenance Best Practices

Aligning the 1TGB302004R5003 on a B5 flange calls for laser leveling to within 0.05 mm—misalignments over that chew bearings in fan arrays, and in explosive zones, always purge enclosures with N2 before cracking seals to flush residuals. Torque flange bolts to 25 Nm dry, using Belleville washers for vibe lock-in, and route cables through PG21 glands with 5x diameter bends minimum; we’ve traced arcing faults to pinched shields in salty atmospheres. For VFD ties, insert du/dt filters if cabling tops 50 m—skipping this spikes dv/dt that etches insulation in long pump runs. Baseline vibration spectra post-commission with a CSI 2140, logging peaks under no-load to flag imbalances early.

Sustain the 1TGB302004R5003 by trending current signatures monthly via clip-on ammeters; deviations over 5% often herald winding shorts, addressable with megger tests at 500V DC quarterly. In dusty coal ops, blast fins with 80 psi air bi-annually, but power down and earth the frame first to bleed static—condensate drains clog otherwise, inviting corrosion in humid tropics. Firmware? Not applicable, but sync PT100 calibrations yearly against a Fluke bath, and inspect keyways for wear during annual teardowns; grease with NLGI 2 every 2,000 hours under load. Archive torque curves from startup for trend analysis, catching efficiency slips before they snowball into drag.