WEGSM1 Manual
WEGSM1 Manual
WEGSM1 Manual
TABLE OF CONTENTS
Motores Sncronos
INTRODUCTION.....................................................................3
ADVANTAGES.........................................................................5
OPERATION CHARACTERISTICS...........................................6
EXCITATION TYPES...............................................................8
CONSTRUCTIVE COMPONENTS.............................................9
ACCESSORIES......................................................................11
CONSTRUCTIVE CHARACTERISTICS...................................12
INSULATION SYSTEM..........................................................13
TESTS...................................................................................13
SYNCHRONOUS MOTOR SELECTION...................................14
APPLICATIONS..........................................................................15
SYNCHRONOUS MOTOR SPECIFICATION......................................16
Synchronous Motors
INTRODUCTION
The word SYNCHRONOUS is originated from Greek. The prefix
SYN means with and CHRONOS means time.
A synchronous motor literally operates in time with or in
synchronism with the power supply system.
Due to the fact the synchronous motors are fitted with special
operating characteristics, industries are more and more using
such motors.
Included in the main reasons for the industries to specify
SYNCHRONOUS MOTORS to drive a wide range of applications
are the high efficiency and the fact they are suitable to operate
as synchronous compensating machines for power supply
factor correction.
In addition to that, these motors also feature high torque, constant
speed under load variation, along with low maintenance cost
allowing major economical and operational advantages to end
users.
Operation Principle
Time
Figure 1
Figure 3
03
Synchronous Motors
Synchronous Speed - The motor synchronous speed (rpm)
is defined by the rotating field speed that depends on the
motor pair of poles (p) and on the power supply frequency (f).
The stator winding can consist of one or more pairs of poles
that are distributed alternatively (one north and another
south) along the magnetic core outer side.
The rotating field goes through a pair of poles (p) at each
cycle. Considering the winding has poles or pair of poles, the
field speed will then be:
rpm
60 . f
p
04
Synchronous Motors
ADVANTAGES
Due to their special operating characteristics, synchronous
motor applications usually result in economical and operational
advantages to end users.
Included in the economical advantages of using synchronous
motors are:
- High efficiency
- Power factor correction
In addition to that, there are other specific operational
advantages of using synchronous motors as follows:
- Special starting characteristics
- Constant speed under load variation
- Reduced maintenance cost
High Efficiency
Associated to the initial purchasing cost of a synchronous motor,
further gains resulting from low operational cost should be
also considered.
On those cases, where just the efficiency aspect is taken into
account when specifying a motor, a synchronous motor with
PF=1.0 is usually the solution.
When the reactive power (kVAr) is not required and only the
actual power (kW) is applicable, the current is minimized
resulting in lower stator winding loss IR.
Once the required field current is the minimum applicable, there
will be lower field winding loss IR. Except for those cases where
high torque is required, the low stator winding losses allow a
synchronous motor with PF=1.0 to be designed in lower size if
compared to a synchronous motor with PF=0.8 of equal power
rating.
Hence, synchronous motor efficiencies with PF=1.0 are normally
higher than induction motor efficiencies of equal power rating.
Efficiency (%)
Induction Motor
05
Synchronous Motors
Special Starting Characteristics
Constant Speed
Large ball mills for iron mines, cement plants and compressors
are few examples of applications that required high starting
torque (150 to 200 % of the rated torque).
Due to power supply system limitations, low starting currents
(locked rotor) are usually required.
A combination of high torque with low starting current can be
better achieved with the application of synchronous motors
without affecting operating characteristics.
Starting current reduction can be usually achieved with a special
design of stator and amortisseur winding.
Starting the motor with reduced voltage is also an alternative
applied so as to have the current reduced, although, with torque
reduction.
OPERATION CHARACTERISTICS
TORQUES
A synchronous motor must be always designed taking into account
driven load characteristics, in addition to torques and inertia.
a) Starting torque
It is the torque that the motor must supply to drive the standstill
load resistant torque, that is, it is the load starting torque.
b) Pull-in Torque
It is the torque that the motor must supply to reach the correct
speed, where the excitation field application will take the motor
to the synchronism (pull-in torque).
Inertia
When driving high inertia loads, synchronous motors are
designed in larger frame sizes so as to meet acceleration
conditions.
The time period the motor takes to accelerate causes amortisseur
winding overheating. Therefore, this motor must be designed in
such a way to meet the starting conditions.
The correct load inertia definition, associated with
motor and load torque analysis are quite important
allowing this motor to meet starting and acceleration
conditions.
Starting
c) Pull-out Torque
It is the torque that the motor must supply to keep the motor
under synchronism in case of momentary overloads with reted
excitation.
06
Synchronous Motors
07
Synchronous Motors
Starting Current
On Brushless synchronous motor starting, the
field winding is short-circuited through the
elechome circuit.
While motor remains on standstill, the field
current frequency is initially equal to power
supply frequency (60Hz for power supply of
60Hz) and reduces as the motor speed
increases.
When the excitation is switched-on, motor
speed must be close to synchronism speed
(around 95% of the synchronism speed), and
the field current frequency will remain around
3Hz.
The stator current also varies on the starting
and then it becomes stable after motor
synchronism.
1) Starting point
Is
Stator Current
Ie
Ie
Is
Stator Current
Ie
Ie
EXCITATION TYPES
08
2. Brushless exciter
Synchronous motors with brushless excitation system are fitted
with a rotating exciter, normally installed on the non-drive end
of the motor.
The exciter operates as an AC generator with the rotor attached
to the motor shaft. The rotor is fitted with a three phase winding
and the stator consists of alternating poles (north and south)
and powered by an independent DC source.
This three phase winding is connected to rectifier bridge. The
current generated on the rotor is rectified and intended to power
the motor field winding. The amplitude of such field current can
be controlled through the
rectifiers that power the
exciter stator field.
Synchronous motors with
brushless excitation require
low maintenance cost once
they are not fitted with
bushes.
Since they are not built
with slip electric contacts,
avoiding
sparking,
synchronous brushless
excitation motors are
recommended for explosive atmosphere applications.
Synchronous Motors
CONSTRUCTIVE COMPONENTS
STATOR
EXCITER
It is intended to supply magnetizing current to the motor field
winding. The brushless exciter consists of rotor, stator, rectifer
bridge and discharge circuit. Tthe static exciter consists of slip
ring and brushes and depends on an external source to power
the motor field.
ROTOR
Depending on motor constructive characteristics and on the
application, rotor can be built with cylindrical or salient poles.
The rotating active parts include rotor ring, field winding and
amortisseur winding.
The field poles are magnetized through the exciter direct current
or directly through slip rings and brushes; they gear themselves
magnetically by the air gap and rotate in synchronism with the
stator rotating field.
The synchronous
motor rotor fitted with
salient poles consists
of shaft, polar ring and
poles.
The poles are built
with laminated steel
plates that are fixed
with steel bar and
Salient pole rotor
welded on the ends.
The field coils are constructed with enameled copper wires or
flat copper bars.
09
Synchronous Motors
Once they have been wound and impregnated, poles are fixed
to the shaft or to the polar ring with the application of bolts
from top or bottom part of the pole, or connected through dov
tail.
The amortisseur winding is fitted in the poles and, depending
on the motor design, it is built with copper bars or other material.
After final assembly and impregnation, the complete rotor is
balanced dynamically at 2 planes.
The synchronous motor rotor of cylindrical poles consists of
shaft, lamination core and pole winding.
The winding is installed in the rotor slots forming the poles.
BEARINGS
Based on the application, synchronous motors can be supplied
with grease-lubricated ball or roller bearings or oil lubricated
sleeve bearings.
Sleeve bearings can be naturally lubricated (self lubricated) or
with a forced lubrication system (independent lubrication
system).
Ball or roller bearings Depending on the speed
and thrusts they are
submitted to, these grease
lubricated bearings can be
supplied either with ball or
cylindrical rollers. On
certain
specific
applications,
special
bearings can be also
supplied.
10
Synchronous Motors
ACCESSORIES
Weg synchronous motors are supplied with standard accessories
required for correct operation and monitoring of the main
components.
When specifying a motor, the end user must inform the required
accessories that should be included in the design and motor
manufacture.
Accessories (supplied as standard)
- Stator winding temperature detectors PT-100
- Bearing temperature detectors
- Space heaters
Bearing PT - 100
Special Accessories
- Brake disc
- Brake
- Vibration detectors
- Encoder
- Frame lifting device
Optional Accessories
- Temperature detectors for air inlet and outlet
- Water flow valve
- Water flowmeter
- Oil flowmeter
- Oil flow sight
- Water flow sight
- Hydraulic unit for bearing lubrication
- Oil injecting system under pressure for motor starting and
stop(Hydrostatic Jacking)
- Oil thermometer (bearings)
- Water thermometer (heat exchanger)
- Air thermometer (Cooling)
- Anchorage plate
Thermometer
11
Synchronous Motors
CONSTRUCTIVE CHARACTERISTICS
Synchronous motor
CONSTRUCTION
Mounting configuration: B3
Enshield bearings
COOLING SYSTEMS
The cooling systems most commonly used are:
- Open self-ventilated motors, Degree of Protection IP23;
- Enclosed motors with air-air heat exchanger, Degree of
Protection IP54 to IPW65;
- Enclosed motors with air-water heat exchanger, Degree of
Protection IP54 to IPW65.
Synchronous motor
Mounting configuration: D6
Pedestal bearings
Open motors
Enclosed motors
Mounting Configuration: D6
Mounting Configuration: D6
Mounting configuration: B3
Mounting configuration: B3
12
Synchronous Motors
INSULATION SYSTEM
On High Voltage Motors - Coils are pre-fabricated with
rectangular shape copper
wire, coated with mica tape
and epoxy resin impregnated.
They are then heated up and
cured resulting in high
winding mechanical strength.
This process is called
polymerization and provides
motor extended life time.
Coils are fitted in the stator slots, insulated from the stator
lamination core with class F (155C) insulating material and
fastened by fiber glass or magnetic wedges.
The copper wires that form the coils are insulated with
appropriate class H (180C)
enamel.
TESTES
Weg synchronous motors are tested
in accordance with IEC34 Standard
in its modern testing laboratory for
low, medium and high voltage
motors in output ratings up to
10,000kVA and voltage range up to
15,000V, with full computerized and
high precision monitoring.
Tests are grouped in three
categories: routine, type and special
tests.
Routine tests are performed on all
motors produced. Besides routine
tests, type tests are normally
performed randomly or under
customer request.
Special tests are performed only
upon customer request.
Routine Tests
Visual inspection test
Air gap checking and bearing tolerances
Winding Ohmic resistance
Insulation resistance.
Temperature and space heater inspection
Bearing and rotation direction marking
Vibration checking
No load test
Short-circuit curve
Hi-pot test
Excitation system test
Special tests
Noise level test
Instantaneous short-circuit
Shaft voltage check
Starting current
Type tests
Temperature rise test
No load curve (V curve)
Overspeed
Loss and efficiency test
Waveform measurement
Polarization index
Synchronous motor starting
13
Synchronous Motors
SYNCHRONOUS MOTOR SELECTION
Service Duty
The correct specification of a synchronous motor rated
power must consider the motor service duty with overload
frequency existing on such duty.
Power factor
Whenever power factor correction is required on a
synchronous motor application, this required power factor
must be specified previously. This means that a motor
designed to operate with unit power factor can not supply
the same rated output power under lower power factor.
Environment characteristics
The environment where the motor will be installed must
be analyzed before specifying such motor. Environment type
defines the Degree of Protection and motor cooling method.
Explosive atmosphere application motors require brushless
excitation.
Ambient temperature and altitude considered when
specifying a motor are 40C and 1000m above sea level.
If motor operation environment presents values above those
mentioned above, it is important to reconsider new data
when specifying this motor.
14
Synchronous Motors
APPLICATIONS
Variable speed
Synchronous motors with variable speed are recommended
for applications with high torque, low speed and wide speed
adjusting range.
Depending on load and environment characteristics, motor
construction for such applications can be supplied with or
without brushes,.
Due to their higher efficiency level, reduced size and higher
output rating capacity, synchronous motors can replace DC
motors on high performance applications.
Fixed speed
Synchronous motor applications with fixed speed are
recommended due to low operational cost once they
offer high efficiency and can be used as synchronous
compensating machines for power factor correction.
Recommended motors for this application are those
with brushless excitation.
On several cases, a motor with lower torque values compared
to standard values can be actually applied. This brings positive
reduction on motor starting current, resulting in less electric
system troubles on starting, along with reduction on mechanical
thrusts resulting from motor winding.
For a correct design and application of Weg synchronous
motors, we recommend to supply complete application data.
15
Synchronous Motors
SYNCHRONOUS MOTOR SPECIFICATION (CHECK LIST)
[ ] Space heater
Voltage (V) ____________
[ ] Winding temperature detectors [PT100 with 3 wires - 1 per phase]
[ ] Bearing temperature detectors [PT100 with 3 wires - 1 per bearing
Notes:
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