Project Region: Europe
Industry: Cement Manufacturing
Application: Kiln Induced Draft (ID) Fan
Rated Power: 2,500 kW
Rated Voltage: 690 V / 50 Hz
Speed: 1,000 RPM / 6-Pole
Motor Type: YKK560-6 Squirrel Cage Motor
Service Factor: 1.10
Cooling: IC666 – Air-to-Air Heat Exchanger with Forced Air Cooling
Protection: IP55
Mounting: B3
A cement plant in Europe required a replacement for its existing 2,500 kW ABB motor driving a critical kiln Induced Draft (ID) Fan.
For a large motor in continuous cement plant operation, replacement can involve significant challenges. Differences in mounting dimensions, shaft configuration, coupling arrangement or terminal box position may require additional site modifications and extend the planned shutdown period.
The customer therefore required a replacement motor that could fit the existing ABB installation with minimal modification while meeting the required electrical and operating conditions.
Our engineering team developed a customized 2,500 kW / 690V YKK560-6 motor as a true 1:1 drop-in replacement for the original ABB motor.
By matching the key mechanical and electrical requirements, the solution allowed the customer to retain the existing installation infrastructure and minimize planned shutdown time.
The original ABB motor was used to drive the cement plant's critical kiln ID Fan.
For this type of application, the motor must provide reliable continuous operation while handling demanding industrial conditions.
The replacement therefore needed to match not only the power and voltage, but also the critical installation dimensions and interfaces.
Our engineering team designed a YKK560-6 squirrel cage motor specifically for this replacement project.
The critical dimensions and interfaces were customized according to the original ABB motor, including:
Center height
Shaft diameter and shaft extension
Mounting dimensions
Foundation bolt arrangement
Coupling interface
Terminal box position
Cable entry arrangement
This 1:1 drop-in approach helped the customer reuse the existing foundation and installation infrastructure, reducing the need for major site modifications.
| Parameter | Specification |
| Project Region | Europe |
| Industry | Cement Plant |
| Application | Kiln ID Fan |
| Original Motor | ABB |
| Replacement Motor | YKK560-6 |
| Rated Power | 2,500 kW |
| Rated Voltage | 690 V / 50 Hz |
| Service Factor | 1.10 |
| Speed | 1,000 RPM |
| Poles | 6 |
| Mounting | B3 |
| Cooling | IC666 – Air-to-Air Heat Exchanger with Forced Air Cooling |
| Protection | IP55 |
| Insulation Class | F |
| Temperature Rise | Class B |
| Ambient Temperature | -20°C to +50°C |
| Installation Altitude | 1,360 m |
The replacement motor was engineered around the original ABB motor's critical mechanical dimensions and installation requirements.
Matching the center height, shaft arrangement, mounting dimensions, foundation bolt pattern and coupling interface helped eliminate major modification work and simplified installation.
Key benefits:
Existing foundation retained
Minimal site modification
Simplified installation
Reduced alignment work
Shorter planned shutdown time
The project required a high-power 2,500 kW / 690V motor for a critical cement plant ID Fan.
The YKK560-6 motor was customized for the existing electrical system and application requirements, providing a robust solution for continuous industrial operation.
The 1.10 Service Factor provides additional service margin for demanding operating conditions and load variations.
The motor features IC666 air-to-air cooling with forced air circulation, providing effective heat dissipation during continuous-duty operation.
This cooling configuration is well suited to large industrial motors where reliable thermal performance is essential for long-term operation.
Cement plants can expose motors to high dust levels, elevated ambient temperatures and continuous 24/7 operation.
The specified site conditions included an ambient temperature of up to +50°C and an installation altitude of 1,360 m.
The customized replacement motor provided a practical alternative to the original ABB motor while minimizing the impact of the replacement on plant operation.
Engineered to match the original ABB motor's critical installation dimensions.
High-power low-voltage motor solution for the existing electrical system.
Additional service margin for demanding operating conditions.
Existing foundation and major installation infrastructure could be retained.
The drop-in design simplified installation and reduced on-site modification work.
IC666 cooling, IP55 protection and Class F insulation for continuous industrial operation.
This project demonstrates our capability to manufacture custom-engineered replacement motors for major international brands, including:
ABB | Siemens | WEG | VEM | TECO | Menzel |Elin| Schorch
For replacement projects, we do not simply supply a standard motor with the same power rating.
Instead, we evaluate the original motor dimensions, electrical data, driven equipment and site conditions, then customize the replacement motor around the existing installation.
This approach is particularly valuable when replacing large motors where foundation modification, coupling changes and extended shutdowns can significantly increase project cost and risk.
After manufacturing and testing, the customized motor was prepared using export-standard packaging for safe international transportation.
The heavy-duty wooden crate was designed to protect the motor during handling, loading and long-distance shipment.
The completed motor was then prepared and dispatched to the European cement plant.
Reinforced Export Packaging for Safe Transportation
If you need to replace an existing ABB, Siemens, WEG, VEM or other industrial motor, we can develop a customized replacement solution based on your existing installation.
1. Original motor nameplate photo
2. GA / dimensional drawing
3. Shaft and coupling dimensions
4. Application and driven equipment information
5. Operating conditions
Our engineering team can evaluate the original motor and develop a replacement designed to fit the existing installation, minimize site modification and reduce planned shutdown time.
