ZCDG Series High-Voltage Low-Speed High-Torque Direct-Drive Permanent Magnet Synchronous Motor

The ZCDG Series represents the leading example of the high-voltage direct-drive technology. It features at the high-voltage directly input design that effectively reduces the line losses, making it ideal for the long-distance power supply or the directly connection to the factory high-voltage grids. At its core, it utilizes high-performance permanent magnets, optimized at electromagnetic design. Combined with its low-speed, high-torque output characteristics, it can directly coupled and driven loads. This completely eliminates intermediate transmission components like the gearboxes, belts or the chains, significantly improving overall system transmission efficiency, reducing maintenance points and potential failure sources and enabling the precise, smooth speed and the position control.

The ZCDG Series is the high-voltage, low-speed, high-torque direct-driven permanent magnet synchronous variable frequency motor, engineered specifically for the heavy-duty, low-speed and precise driven applications. By integrating the high-voltage power supply, the high-efficiency permanent magnet synchronous technology and the direct-drive configuration, it achieves exceptionally high torque output without the gear reduction devices. It offers significant advantages including the high efficiency, the low vibration, the precise control and the reliable operation, making it suitable for the various demanding in the industrial environments.

Key Features

The ZCDG Series direct-drive permanent magnet motors feature a high-voltage input design, incorporating high-performance permanent magnets and an optimized electromagnetic solution to deliver high-torque output at low speeds. By directly coupling and driving the load, these motors eliminate intermediate transmission components like gearboxes, enhancing overall system efficiency and enabling precise control. With rated voltages covering 3-10 kV, they are suitable for direct connection to high-voltage grids, reducing line losses. Their robust construction, strong environmental adaptability, and smooth, low-noise operation make them ideal for heavy-duty direct drive applications in industries such as mining, ports, and building materials.

High Efficiency & Energy Savings: Utilizes premium permanent magnet materials and an optimized electromagnetic design, achieving efficiency class IE4 or higher. It offers high overall efficiency across a wide operating frequency range, significantly lowering long-term energy consumption.

High-Torque Direct Drive: Capable of delivering extremely high torque at low speeds, it directly drives the load. This eliminates the need for reduction gearboxes, simplifying the system structure while improving transmission efficiency and reliability.

Precise Control: When paired with a compatible variable frequency drive (VFD), it achieves precise, wide-range speed and torque regulation with fast response and smooth operation, meeting the demands of high-precision process control.

High-Voltage Advantage: The rated voltage range of 3kV to 10kV allows for direct connection to high-voltage power grids, reducing investment in power supply lines and minimizing line losses to lower system operating costs.

Robust & Reliable: Features a reinforced mechanical structure, a high protection rating, a superior insulation system, and extended bearing life. Its strong environmental adaptability and ease of maintenance ensure long-term, stable operation.

Technical Specifications

Power Range: Covering 200 kW to 3000 kW, the motor adapts to various industrial load demands. Its logical power gradation facilitates precise model selection, meeting the power drive requirements of equipment across different scales.

Rated Voltage: Supports high-voltage levels of 3 kV, 6 kV, and 10 kV, enabling direct connection to high-voltage grids. This reduces line losses, simplifies the power distribution system, and is suitable for long-distance power supply or high-voltage distribution environments.

Efficiency Class: Meets the IE4/IE5 Super-Premium efficiency standards. Utilizing high-performance permanent magnet materials and an optimized electromagnetic design, it maintains high efficiency across a wide load range, with energy consumption significantly lower than traditional drive solutions.

Power Factor: The rated power factor exceeds 0.95, offering excellent grid compatibility. It effectively reduces reactive power loss, alleviates grid burden, and enhances the overall efficiency of the power supply system.

Protection Level: Designed with an IP54/IP55 protection structure. The totally enclosed construction effectively guards against dust and water ingress, adapting to complex industrial environments such as those with high dust or moisture levels, ensuring long-term reliable operation.

Frame Construction: Utilizes high-strength cast iron or welded steel plate construction, offering excellent impact resistance and high rigidity. This effectively bears the substantial torque loads during motor operation, ensuring minimal mechanical deformation under heavy-duty conditions.

Cooling Method: Equipped with either an IC416 air-to-air or IC411 forced-air cooling system. Both provide high heat dissipation efficiency, ensuring the motor’s temperature rise remains within optimal limits during low-speed, high-torque operation for long-term stability.

Insulation Class: Features a Class H insulation system with superior high-temperature performance. It adapts well to temperature variations from prolonged heavy-load operation, providing reliable electrical protection and ensuring long service life.

Mounting Options: Supports various mounting configurations including IM B3, B5, and B35. The flexible structural design facilitates adaptation to different equipment’s spatial and interface requirements, enhancing system integration convenience.

Bearing Type: Fitted with heavy-duty rolling bearings that offer excellent load capacity and impact resistance. The specialized lubrication and sealing design effectively handles both radial and axial loads, ensuring stable, long-life bearing operation.

Starting Torque: Achieves 200% to 300% of rated torque, providing powerful direct-on-line starting capability. It easily drives heavy-duty equipment to a smooth start without the need for auxiliary starting devices, significantly enhancing system reliability.

Maximum Torque: Offers a maximum torque of ≥250% rated torque, featuring strong overload capacity. It can withstand instantaneous impact loads and short-term overload conditions, ensuring stable operation even during abnormal situations.

Noise Level: Operating noise is ≤85 dB(A). Through optimized electromagnetic design and structural vibration damping measures, operational noise is significantly reduced, providing a quieter work environment that complies with environmental and occupational health standards.

Vibration Grade: Vibration velocity is ≤2.8 mm/s. Precision dynamic balancing and structural optimization ensure smooth operation across all working conditions, minimizing impact on equipment foundations and extending service life.

Duty Cycle: Designed for S1 continuous duty operation, capable of 24/7 uninterrupted running. The optimized cooling system ensures stable temperature rise under prolonged full-load conditions, meeting the demands of continuous production.

Operating Temperature Range: -20°C to +40°C. The optimized insulation system and low-temperature resistant materials ensure stable performance in both cold winters and hot summers, accommodating diverse climatic conditions across different regions.

Altitude: Standard operation is rated for altitudes ≤1,000 meters. For specific requirements in high-altitude regions, customized design services are available to ensure the motor maintains rated performance and long-term reliability in low-pressure environments.

Safety Certifications: The product is certified with China Compulsory Certification (CCC), complying with national electrical safety standards. Our comprehensive certifications guarantee reliable quality and safety for industrial applications.

Warranty: Backed by a 24-month warranty, which includes free repair services and technical support. Our complete after-sales service system ensures customer peace of mind and helps reduce lifecycle maintenance costs.

Standards Compliance: The product strictly adheres to GB National Standards and IEC International Electrotechnical Standards, meeting industry specification requirements. High standards compliance facilitates easier equipment selection, system integration, and international market application for users.

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Motor Selection Guide and FAQ

Motor Selection Guide
1. Define Basic Parameters
Power & Speed:
Determine the required rated power based on load characteristics and define the motor pole count and speed range according to your equipment’s operational speed.
Voltage & Frequency:
Confirm your power supply standard (e.g., 380V/50Hz, 480V/60Hz). Custom designs are available for special voltage requirements.
Mounting Type:
Specify IEC standard mounting (e.g., B3, B5, B14). Custom the flanges & bases are also supported.
2. Consider Operating Environment
Protection Rating (IP):
IP55 for standard environments. IP65 is recommended for damp or dusty conditions. Hazardous areas require Ex D/Ex E certifications.
Insulation Class:
Class F (155°C) for general use. Class H (180°C) insulation is advised for high-temperature environments.
Cooling Method:
Self-ventilated (IC411) for standard applications. Forced air or water cooling is available for enclosed spaces or high-power-density scenarios.
3. Match Load Characteristics
Starting Torque:
Consider starting torque for fan/pump loads. Verify locked-rotor torque for conveying equipment.
Duty Cycle:
Standard motors are suitable for continuous operation (S1). Frequent start-stop cycles (S5) require reinforced bearings and insulation.
Efficiency Requirement:
Select IE3/IE4/IE5 efficiency classes based on annual operating hours. Ultra-premium efficiency (IE5) motors offer the lowest total cost of ownership for long-running applications.
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