Three-Phase Synchronous Motors
Contents
1. lt Centre height mm aW 2 1 120 1 000 104 9 eb IbBl6je 2 4 8 900 7 6 5 800 4 710 3 2 630 103 9 8 7 6 5 4 3 Correlation Power speed centre height 5 6 7 8 9108 2 n min 1 e Thermal class F utilization B e xd 11 16 e Rated voltage lt 6 kV e Excitation brushless with brush e Air to water heat exchanger with forced ventilator 2 Type designation The Sachsenwerk model designations consist of let Letters Position 1 5 ters and numbers Numbers Position 6 9 Numbers letters Position 10 14 Position 1 4 and 5 6 and 7 8 and 9 10 and 11 12 to 14 variable depending on the machine type DMMV X 2 1 06 4 8WID 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Type of current E Single phase AC D Three phase AC M Multiple phase AC Machine type COAZDANADWDALY Co E A F L lt SVOOZZWHNAID AC current asynchronous generator AC current asynchronous squirrel cage rotor motor AC current asynchronous slip ring rotor motor with BAV AC current asynchronous slip ring rotor motor without BAV AC current synchronous generator with slip rings AC current synchronous generator without slip rings AC current synchronous motor with slip rings AC current synchronous motor without slip rings AC current commutator motor AC current single housing2. Open cooling circuit 18 pumped through the heat exchanger by means of additional forced ventilators 6 6 Closed loop control 6 6 1 Integration into E systems When the synchronous motor is operated directly off the mains supply the excitation unit represents the control link between the E system and the motor This applies to both brushless and static excitation systems which have analogue or digital excitation control Depending on the size of the motor and the configuration of the E system a greater or lesser number of control functions are performed or assessed by the excita tion unit Key features of the synchronous machine are achieved through open and closed loop control of the excitation as a result of which the scope of functions of the excitation unit may vary toa great extent depending on the specific requirements from the plant project Excitation control functions are used among other things to influence the start up behaviour the stability during non sta tionary processes and the re synchronisation behaviour The open loop excitation control enables the following func tions to be implemented within the program e Anti blocking protection e Start up monitoring e Deliberate synchronisation e Crank angle control e Triggering of protection systems Closed cooling circuit air to air e Asynchronous running protection with re synchronisation e Setpoint adjustment e Controller status control Auto Ma
3. Mechanical vibrations correspond to the limits specified in EN 60034 14 and are proved in the test lab e Vibration monitoring is performed without an evaluation device 31 13 Technical data Power range Power range Brushless high voltage synchronous motors 6 kV Brushless high voltage synchronous motors 10 kV 50Hz cos q 0 9 Number of poles 4 12 Thermal class F utilization B 50Hz cos 0 9 Number of poles 4 12 Thermal class F utilization B Typ Centre height Power output Typ Centre height Power output DT mm 1500 min 1000 min 750 min 600 min 500 min DT mm 1500 min 1000 min 750 min 600 min 1 500 min 5018 500 1250 900 630 500 400 5018 500 1120 800 560 5023 500 1600 1120 800 630 500 5023 500 1400 1000 700 6321 630 2800 2000 1400 1120 900 6321 630 2500 1800 1250 1000 800 6324 630 3150 2250 1600 1250 1000 6324 630 2800 2000 1400 1120 900 6327 630 3550 2500 1800 1400 1120 6327 630 3150 2250 1600 1250 1000 6329 630 4000 2800 2000 1600 1250 6329 630 3550 2500 1800 1400 1120 8030 800 7100 5000 3550 2800 2250 8030 800 6300 4500 3150 2500 2000 8033 800 8000 5600 4000 3150 2500 8033 800 7100 5000 3550 2800 2250 8036 800 9000 6300 4500 3550 2800 8036 800 8000 5600 4000 3150 2500 8040 800 10000 7100 5000 4000 3150 8040 800 9000 6300 4500 3550 2800 1038 1000 18000 12500 9000 7100 5600 1038 1000 16000 11200 8000 6300 5000 1042 1000 20000 14000 10000 8000 6300 1042 1000 18000 1250
4. IEC 60034 18 several parts as well as DIN ISO 10816 Evaluation of the vibrations of machines ISO 10816 through measurements of non rotating parts several parts DIN ISO 8821 Mechanical vibrations agreement on the ISO 8821 feather key type when balancing shafts and connecting parts DIN ISO 1940 Requirements for the balancing quality of ISO 1940 rigid rotors several parts DIN ISO 7919 Measurement and evaluation of ISO 7919 mechanical vibrations In the case of explosion proof machines the fundamental safety requirements are ensured by designs that meet the standards DIN EN 50014 VDE 0170 0171 part 1 DIN EN 60079 0 IEC 60079 0 DIN EN 50016 VDE 0170 0171 part 3 DIN EN 60079 2 IEC 60079 2 DIN EN 50019 VDE 0170 0171 part 6 DIN EN 60079 7 IEC 60079 7 DIN EN 50021 VDE 0170 0171 part 16 DIN EN 60079 15 IEC 60079 15 On request the products can be supplied in accordance with other standards such as IEC standards currently being ratified as well as in accordance with special industry regulations such as ZLM additional supply agreements for high voltage elec trical motors in power plants regulations from all of the ma jor ship classification associations or the Shell specification 4 Synchronous motors for constant sped applications 4 1 Voltage and frequency In the basic design the motors are dimensioned for a rated voltage of 6 kV and a rated frequency of 50
5. 30 If the customer prefers to perform the installation and com missioning themselves or have this work done by a third party then the performance of this work must be verified in section 9 test certificates logbook of the VEM Operation and Service Manual or by other means Failure to comply with this require ment will absolve VEM from any liability or warranty obligations The VEM Operation and Service Manual is delivered with the machine If contractually agreed the documentation can also be sent separately to the buyer or operator I EN hOPH KEN 0 HIET TENN EA pr GIOTAZOB KON V HP FITABHA JORIACT 12 General instructions If not expressiy requested and offered otherwise the machine is designed as follows e t is built with the insulation system VEMoDUR e t is painted in accordance with Sachsenwerk Standard SW N 170 004 which is based on DIN EN ISO 12944 ISO 12944 and applicable standards e The machine s direction of rotation is right when looking at the drive D end The connecting box is positioned on the right e The cooler is located on the machine and the water connec tion is on the left when looking at the drive D end e Water cooler up to the connecting flange without monitoring on the water side e Without cable stuffing socket e PT 100 for winding and storage in 2 wire switch without trigger device from terminal box connection in 2 3 and 4 wire design
6. 6 DMMYZ 1038 6 DMMYZ 8027 8 DTMYZ 1025 10 EExp II T3 DTKYY 1131 6W DTMYZ 3070 16 DMMYZ 9036 6 DTKVY 4937 30W EExp II T3 DMMYZ 3067 16 DTKVY 3253 30W EExp II T3 Qty Power output kW 4 000 4 000 5 000 18 500 22 400 2 719 6 000 3 000 3 250 12 500 15 000 6 300 23 500 5 000 11 700 Rated voltage kV 3 0 2 0 2 0 3 3 6 6 1 35 1 65 6 0 2 9 1 75 1 575 10 0
7. Hz with a power factor of cos q 0 9 ever excited Voltage and frequency fluctuations during operation are pos sible in agreement with the stipulations in DIN EN 60034 1 VDE 0530 part 1 IEC 60034 Motors for voltage ranges 3 3 kV have higher motors for voltage ranges 6 6 kV lower rated outputs with the same construction models 4 2 Rated power output and heat generation The rated outputs stated in the summary of supply hold for continuous operation S1 at rated frequency rated voltage installation altitude 1 000 m above sea level and a maximum cooling air entry temperature of 40 C or cooling water entry temperature of 27 C The maximum winding temperatures correspond to thermal class B in accordance with DIN IEC 60085 VDE 0301 part 1 IEC 60095 measured using the re sistance method 10 Motors can be supplied with a maximum permissible temper ature rise in accordance with thermal class F 4 3 Direction of rotation As a general rule the synchronouse motors must only be op erated in the agreed direction of rotation Special fans can be used in cases requiring bi directional operation Fans for bi directional operation cause greater frictional losses and therefore achieve a lower efficiency 4 4 Overload capacity The synchronous breakdown torque is 1 5 1 35 times the rated torque for salient pole motors and smooth core rotor motors respectively Depending on the drive task in hand these values can be
8. in the motor The excitation current control serves for servicing and manu al operation purposes as well as for simple operation from a higher level control In the process the internal setpoint is adjusted via HIGH LOW signals Depending on the project requirements more or less com plex analogue or digital devices are used Basic functions e Reactive power control e Digital setpoints e Manual operation e Excitation current control e Limitation of excitation current e imitation of over and under excitation 20 Possible upgrades e Remote setpoint processing e External actual value processing Limitation of rotor displacement angle e Stator current limitation Reactive power limitation Other functions required in addition to the above should be discussed with VEM 6 7 Excitation The synchronous motors are supplied as brushless versions as standard Alternatively excitation via a slip ring arrangement is also avail able The brushless version is maintenance free and can also be used when the motor is operated in an atmosphere with an increased risk of explosion The rotating brushless excitation unit excitation machine rec tifier start up thyristor protective circuitry and if applicable start up resistor can be arranged both inside and outside the machine Excitation cabinet Depending on the required mode of operation for the motor the excitation machine is laid out as either e a
9. mica foil bands Main insulation mica fibreglass bands groove and core chuck contains accelerator low adhesive Impregnating material epoxy resin The components are optimally matched to each other The insulation class F has been confirmed through many years of operating experience and functional evaluation as per DIN EN 60034 18 31 VDE 0530 part 18 31 IEC 60034 18 31 To guarantee the quality of the insulation system all compo 26 nents are subjected to a receipt inspection in accordance with DIN EN ISO 9001 ISO 9001 During the impregnation process the insulation is subjected to a constant control system whereby characteristics such as viscosity of the resin e impregnation and curing temperature pressure maintaining times e under and overpressure e pressure impregnation e are checked and documented The insulation is cured in rotation Vacuum pressure impregnation guarantees a high mechanical strength core chuck rigidity and outstanding electrical strength This holds especially for the distance sparkover volt ages Rated surge voltages in accordance with DIN EN 60034 15 VDE 0530 part 15 IEC 60034 15 are guaranteed for all machines with a great degree of reliability see table extract Insulation level of rotating electrical machines with stator pulled coil windings in accordance with DIN EN 60034 15 VDE 0530 part 15 IEC 60024 15 extract The insulation system i
10. pulse pattern output filter In the case of converter fed machines the converter type must be stated in the inquiry Stator for rolling mill drive type DMMYZ 2246 6Y 6 Design description 6 1 Stator The stator housing is a welded construction comprising end walls and intermediate walls with support ribs bars and sheet casing It stands on base plates on the foundations The stamping pack consists of insulated dynamo sheet round plates or overlapped layered dynamo sheet segments and it is axially tensioned over end plates with press pins and welded on bars On machines with a diameter of up to 4 000 mm the stamping pack is wound with whole pulled coils fully impreg nated according to the VPI process and shrink fitted into the stator housing On larger machines the insulated dynamo sheet segments are overlapped and layered on guide bars in the housing tensioned and then wound with vacuum pressure impregnated trans posed conductor rods or pulled coils which are premanufac tured according to the resin rich process The three phase stator winding lies in the open slots of the stamping pack Depending on the rated power output it is im plemented as a double layer whole pulled coil or double layer transposed conductor winding With the whole pulled coil the conductive material is made of flat copper wire which is insulated with mica foil For the con ductors of the transposed conductor winding twisted in the slot part
11. rotor in solid pole design The spindle with the pole cores consists of a forged piece which is machined on all sides Pole coils made of edge wound flat copper are positioned with insulation on the pole cores In order to improve heat dissipation and mechanical stability Salient pole rotor laminated for piston copressor drive type DTKVY 2523 16WS they are cast in resin Forged pole covers are screwed onto the pole cores Salient pole rotors with laminated poles A cast rotor body is drawn onto a forged spindle or flanged onto a forged spindle The poles are made of layered plates then pressed onto the end plates and secured with bolts The poles are wound di rectly with insulated flat copper wire and VPI impregnated Alternatively insulated pole coils which consist of edge wound flat copper are set onto the pole cores and cast in resin to improve heat dissipation and mechanical stability There are additional slots on the pole covers which take the start up rods The complete poles are screwed onto the rotor bodies or they are attached with hammer head grooves and wedges under high circumferential forces The ends of the start up rods are short circuited with segments 6 3 Connecting boxes All connecting boxes are designed to protection class IP55 in their basic designs Wiring connecting box The wiring connecting box is positioned on the side wall of the stator housing The box features a welded 2 part design The low
12. 0 9000 7100 5600 1047 1000 16000 11200 9000 7100 1047 1000 20000 14000 10000 8000 6300 1053 1000 18000 12500 10000 8000 1053 1000 22500 16000 11200 9000 7100 C3 2 3 ow 14 Industry solutions Excerpt Year of delivery 2004 2003 2003 2003 2003 2002 2002 2001 2001 2000 2000 2000 1999 1999 1997 34 Ordering party DMS ZI LILLE SECLIN Alstom Alstom Linde AG Lungi Siemens AG Siemens AG Alstom Alstom Linde AG STN Atlas Marine Electronics Siemens AG Salzgitter Anlagenbau Alstom Mannesmann Demag Salzgitter Anlagenbau Object Driven equipment Quingdao China Rolling mill drive Rasselstein Deutschland Rolling mill drive TKS Bruckhausen Deutschland Rolling mill drive Kollsnes Norwegen Turbocharger compressor drive LDPE Marun Iran Piston compressor drive CISA RCM Brasilien Coiler drive CISA RCM Brasilien Stand drive Corus Staal B V Niederlande Shearing drive Lesum Il Deutschland Piston compressor drive Luftverdichter Linz sterreich Air compressor drive SKY II Norwegen Propeller motor Pingxiang China Block drive LDPE Projekt BASELL Frankreich Piston compressor drive Nosta Russland Dual drive Novy Urengoy GUS Piston compressor drive Machine type DMMYZ 8044 6Y DMMYZ 9040 4Y DMMYZ 2246 6Y DTKFU 1044 4WS EExp IIA T3 DTKVY 4931 30WS EExp II T3 DMMYZ 8040
13. 60079 7 IEC 60079 7 27 9 Inspections An effective quality assurance and management system guar antees the optimal value and quality of the motors Every mo tor is subject to an internal individual inspection The results of the inspections are documented in an inspection log This is part of the delivery documentation Individual inspections e Visual inspection identification completeness condition of construction quality of assembly brush type and dimen sions etc Air gap measurements if permitted by the construction e nsulation resistance of the windings temperature probes anti condensation heaters bearings inspection performed during assembly e Ohmic resistances of the windings temperature probes anti condensation heaters Measurement of the magnet wheel impedance e Setting of the magnetic centre for sliding bearings e dling characteristic curve for determining magnetic and frictional losses calculation check of efficiency if required e Check of direction of rotation e Inspection of the voltage geometry e Winding checks e Vibration severity measurement e Short circuit characteristic curve and loss measurement generator method e Determination of the SPM level if corresponding feature is available e Current overload test e Winding check high voltage test e Functional capability of the accessories Type inspections If the customer wishes additional inspections can be per formed wi
14. VEM group Th ree Phase VEM Sachsenwerk GmbH VEM motore GmbH Synchronous Motors VEM motors Thurm GmbH Keulah tte GmbH 800 to 35 000 kW VEM Products Low voltage machines Three phase asynchronous motors with squirrel cage and slipring rotor up to 500 kW Rollertable motors up to 160 kW Explosion protected motors up to 630 kW Crane motors and marine motors Special motors with brake forced ventilator encoder Compact drives up to 22 kw Energy saving motors Built in motors Tree phase asynchronous generators High voltage machines High voltage asynchronous motors up to 28 MW High voltage synchronous motors up to 35 MW High voltage synchronous generators up to 45 MVA Traction machines Windpower generators up to 5 4 MW Foundry products Customer made castings Fittings valves hydrants Sliding valves flap valves Your contact SWD 04 007 E 0405 GD Printed in the Federal Republic of Germany Changes reserved www vem group com we get things moving e Page Foreword Summary of supply Synchronous motors with constant speed and Too DM RT med 4t gt brushless excitation Synchronous motors with speed control Type designation Norms and regulations Synchronous motors for constant speed applications Voltage and frequency Rated power output and heat generation Direction of rotation Overload capacity Start up Modifications vA Converter fed variable speed C nh synchr
15. age of contract prepa ration a risk evaluation of possible ignition dangers should be conducted and measures to minimise risk should be adopted if applicable For high voltage machines with rated voltage U 26 kV a sys tem test for the complete insulation system under an ignitable atmosphere remains necessary The corresponding certifi cate of the PTB Braunschweig as a recognized test authori ty is available for a Sachsenwerk insulation system VEMoD UR VPI 155 Synchronous motor 3 5 MW extruder drive EEx p 25 8 Universal VEMoDUR insulation system The operating reliability of electrical machines is determined to a large extent by the quality of their winding insulation The insulation technology at Sachsenwerk has always been char acterised by technical solutions which in terms of their quality parameters meet applicable international standards and thus ensure products which are highly reliable and offer their oper ators a long service life The VPI technique vacuum pressure impregnation is used for high voltage machines The associated insulation system VEMoDUR VPI 155 was developed at Sachsenwerk and is registered as a trademark The designation VEM stands for Vereinigter Elektromaschinenbau and DUR for the duro plastic behaviour of the insulations with synthetic adhesives that are used This system contains the following listed main components for the stator windings Winding insulation
16. amping pack length encoded Nu mber of poles speed Additional letter for rework stage and special conditions Letter codes for special winding designs 3 Standards and regulations The motors comply with the applicable DIN standards and the DIN VDE regulations For the basic designs these in clude in particular DIN EN 60034 VDE 0530 and IEC 60034 with its parts Part 1 Dimensioning and operational behaviour DIN EN 60034 1 VDE 0530 1 IEC 60034 1 Part 2 Methods for determining the loss of efficiency DIN EN 60034 2 VDE 0530 2 IEC 60034 2 Part 4 Methods for determining key synchronous machine variables from tests DIN EN 60034 4 VDE 0530 4 IEC 60034 4 Part 5 Classification of protection classes DIN EN 60034 5 VDE 0530 5 IEC 60034 5 Part 6 Classification of cooling methods DIN EN 60034 6 VDE 0530 6 IEC 60034 6 Part 7 Classification of design types DIN EN 60034 7 VDE 0530 7 IEC 60034 7 Part 8 Connection designations and direction of rotation DIN EN 60034 8 VDE 0530 8 IEC 60034 8 Part 9 Noise limits DIN EN 60034 9 VDE 0530 9 IEC 60034 9 Part 14 Mechanical vibrations DIN EN 60034 14 VDE 0530 14 IEC 60034 14 Part 15 Surge voltage ratings DIN EN 60034 15 VDE 0530 15 IEC 60034 15 Part 16 Excitation systems for synchronous machines DIN EN 60034 16 VDE 0530 16 IEC 60034 16 Part 18 Functional evaluation of insulation systems DIN EN 60034 18 VDE 0530 18
17. bearing shell of the sliding bearing on the ND side is insu lated to prevent bearing currents The sliding bearings are usually designed as floating bearings i e the motor rotor is guided via a coupling with limited axial clearance by the supporting bearing of the machine It is also possible to use a locating bearing if no axial forces are directed from the machine or coupling onto the motor spindle Special bearing shells are used for applications where axial forces need to be absorbed The sliding bearings are preferably cooled via heat dissipation through the surface of the bearing housing If the operating conditions do not allow this then the bearings can also be cooled with rinsing oil or via an integrated water cooler At low speeds or in applications with greater rotor masses a hydro static rotor boost is used Lubrication is provided by means of lubricating oils with a vis cosity class which is governed by the operational data of the sliding bearing Use of other oils must be agreed with VEM Appropriate oil supply units are available from VEM for the use of rinsing oil to cool the bearings The bearing shells on the ND end are insulated to prevent bear ing currents Monitoring is preferably implemented via Pt100 temperature measurements A version with vibration dampers is available For connection to a rinsing oil system we can supply choke screws which are used to control the flow rate of the oil and a flow rate di
18. chine which is to be driven As a general rule an attempt is made to ensure maximum operational safety and reliability and maximum ser vice life Rolling bearings The motors are equipped with DIN standard rolling bearings A deep groove ball bearing is used as a guide bearing on the D end At absorbs the radial and low axial loads A cylinder roller bearing is used as a floating bearing on the ND end Under increased mechanical loads and higher speeds the deep groove ball bearing on the D end is reinforced with a cylinder roller bearing At lower speeds a deep groove ball bearing is used at the ND end instead of the cylinder roller bearing as a floating bearing in an axial position In applica tions where the synchronous motor is designed to absorb additional axial loads a special bearing with pre loaded an gular contact ball bearings is used The axial loads and radial loads should be quoted in the re quest specification All rolling bearings are lubricated with lithium base saponified grease of consistency class 3 Rolling bearings 16 The bearing modules are equipped with an automatic grease quantity control system This ensures perfect lubrication lev els after re greasing In accordance with the specifications in the motor documen tation the bearings must be regularly re greased with the in dicated type and quantity of grease in order to make sure that the bearings achieve their nominal service life This is don
19. clude e greater power and speeds can be achieved with the engine robust design which is adapted to the drive tasks low maintenance operation high degree of efficiency speed setting can be used with a wide field suppression range commutation reactive power load controlled inverter can be taken over Design concept In contrast to conventional synchronous machines the design of converter fed machines also takes the following aspects into account e dimensioning of the stator winding insulation for operation on a direct converter or indirect converter and the relevant rated voltage Synchronous motor for frequency converter operation rolling mill drive type DMMYZ 8044 6Y 12 e dynamic and quasi stationary overload torques on rolling mill motors e adaptation of the electromagnetic parameters to the special requirements of speed controlled drives e additional insulation of the bearings on the D end and spindle grounding brush depending on the type of converter used Depending on the system components and drive specific requirements the motors can be implemented in the form of smooth core rotor motors or salient pole motors or with without brushes The operation of the motors on frequency converters results among other things in a higher noise level than with sinusoidal mains power networks In the case of converters the increase in the acoustic pressure level depends on e converter type e pulse frequency e
20. converter oling type protection class Ventilated cooling self cooling without add ons IP00 IP10 IP20 IP21 IP22 IP23 Ventilated cooling self cooling with add ons IP23 Ventilated cooling self cooling pipe connection with internal fan IP44 IP54 IP55 Draft ventilation forced air cooling supplemental ventilation unit or pipe connection IPOO IP10 IP20 IP21 IP22 IP23 IP24 Draft ventilation forced air cooling pipe connection IP44 IP54 IP55 Circulation cooling self cooling air to air cooler IP44 IP54 IP55 Circulation cooling self cooling air to water cooler IP44 IP54 IP55 Circulation cooling forced air cooling with air to air cooler with additional ventilation unit IP44 IP54 IP55 Circulation cooling forced air cooling with air to water cooler with additional ventilation unit IP44 IP54 IP55 Circulation cooling self cooling or forced air cooling with gas as refrigerant except air all protection ratings Surface cooling self cooling with cooling holes IP44 IP54 IP55 Surface cooling self cooling with cooling fins IP44 IP54 IP55 Surface cooling self cooling without fan IP44 IP54 IP55 Surface cooling forced air cooling with water cooling jacket IP54 Surface cooling forced air cooling with additional ventilation unit IP54 Design type encoded Bearings deviating voltage and frequency Explosion protection construction high load start etc Shaft centre height encoded St
21. e using M10x1 flat grease nipples in accordance with DIN 3404 The bearings for smaller synchronous motors are equipped with a storage receptacle for the old grease Provided the proper re greasing schedule is followed this receptacle is large enough for the calculated service life of the bearings Bearings for larger motors have storage receptacles for old grease which can be emptied from outside The bearings are sealed to the inside of the motor and to the outside with gap seals They are maintenance free and protect against penetration of dust and water The bearing heads on the ND end are insulated against the motor housing to prevent bearing currents The rolling bearings are monitored via Pt100 temperature measurements Versions can be implemented with vibration monitoring Sliding bearings Sliding bearings Depending on the design of the machine the sliding bearings can be designed as flange bearings or as pedestal bearings or they can be centred on the end plate The types of bearing used include bearings with a split hous ing split bearing shells and split lubricating rings and sealing rings This enables bearings to be serviced and sealing rings to be replaced without the need for disassembly of adjacent motor component groups or couplings The protection class of the bearings in their basic design is IP 44 Higher protection classes IP54 or IP55 can be achieved by using additional seals gaskets The
22. e at higher speeds This design is mechanically robust and thanks to the large heat capacity of the pole cover it en ables an asynchronous start up with relatively large external mass moments of inertia Smooth core rotor for rolling mill drives type DMMYZ 8027 8W 14 6 2 2 Description of the design and layout The rotors can be designed as smooth core rotors or salient pole rotors Salient pole rotor The stamping pack which is made of insulated dynamo sheet round plates is shrink fitted to a forged spindle The stamp ing pack is axially loaded with insulated with press pins With larger synchronous motors spider shafts are used on to which the rotor plate segments are positioned and keyed The excitation winding is laid into the slots of the stamping pack Lacquer fibreglass insulated profiled wires are used for the excitation winding The rotor is fully impregnated in accor dance with the VPI method Slots are distributed evenly around the outer circumference of the rotor stamping pack to take the start up rods The start up rods are hard soldered at the ends with short circuit discs They also form the short circuit cage for direct start ups For start ups with relatively high mass moments of inertia or with high load moments specially designed high rod start up cages are used Special designs are used to stabilise the rotor winding in ap plications with special operating loads e g rolling mill drives Salient pole
23. embly plate in the rear of the cabinet The open and closed loop controllers are mounted on a piv oting frame The pivoting frame is omitted on smaller units In this case the open and closed loop controllers are also housed on the assembly plate 6 6 3 Function of the excitation system In principle the closed loop control of a synchronous motor via its excitation takes place under the aspects of drive stabili ty and the specific requirements of the E system or mains supply Although these aspects are not mutually exclusive the configuration of the overall system should be carefully balanced in both their favour Closed loop reactive power control is generally utilised which operates with a subordinate auxiliary excitation current con trol on brushless systems as this provides good settling times As an alternative cosj control can also be used as a derived form of reactive power control Measured values which are only indirectly connected to the synchronous motor can also be used as the actual values for the controller as a result of which the behaviour of the entire network island is influenced Similar effects can also 19 be achieved variable setpoint specifications which are gener ated in a higher level control A range of limiting controllers are used primarily to prevent a loss of stability of the motor The limitation of the rotor displacement angle is based on a system of detecting the angle via inductive sensors
24. er complex during synchro nous mains operation 6 7 3 Asynchronous low load start up In the event of operation without supply from a converter and with a relatively low load moment the brushless synchronous motor can also start up asynchronously provided provisions are in place in the rotor circuit for the AC start up current in the excitation coil The positive half wave of the AC start up current flows through the rectifier diode bridge which is already in place The nega tive half wave flows anti parallel through voltage controlled thyristors to a diode branch of the rectifier bridge The voltage controlled triggering of the thyristors is achieved by virtue of the current forcing character of the AC start up current The thyristors are reliably turned off during operation by being connected to the AC voltage of the excitation machine by means of voltage zero bt dk exciter mains converter motor Boma Schematic diagram showing a rotor with connected converter 22 6 7 4 Asynchronous high load start up To start up the synchronous motor without a supply from a converter against a relatively high load moment the excitation coil must be terminated with an optimised start up ipedance This has the effect that the asynchronous moment of the mo ment is increased pull up torques are prevented and tenden cies to vibrate are significantly reduced If the start up imped ance was to remain connected afte
25. er part is bolted to a plate which makes up part of the housing There is a designated breaking point in the lower part which is de signed to relieve pressure in the event of a short circuit Connecting box with outgoing star point with current trans former for differential protection Bores in the lower part take short circuit proof cast resin in sulators which contain duct bolts which are secured against rotation They are soldered to the cable to the cable outlets of the sta tor winding The connection on the mains side is provided by means of cable sleeves which are screwed to the duct bolts The cable outlet is to the bottom Screw type cable connec tor terminals are used on single conductor cables A special module is used for three conductor cables containing sealing rings which can be cut out and a pull relief pressure ring Start point box The star point can be located in a second box opposite the cable connecting box Current transformers can be installed on request not on EEx e applications Auxiliary connecting box Additional connecting boxes for connecting excitation devices monitoring devices anti condensation heaters etc are posi tioned on the stator They are made of a low corrosion cast aluminium alloy The cable outlets are provided via screw type terminals Stator connecting box 15 6 4 Bearings The type of bearings used depends on the requirements re sulting from the mechanical loads and the ma
26. lacquer fibreglass insulated flat copper wires are used and fastened as a wire bundle with mica prepreg The main insulation of the coils or rods consists of mica fibre glass tape To avoid corona discharges a low impedance mica protective cover is installed in the slot part and a high imped ance protective cover is installed in the slot exit The fully insulated conductor packages are fixed in the slots using slot connectors The winding heads are safely supported against the mechan ical loads arising during switching operations due to binding spacer pieces or retaining rings The switch connections are hard soldered at the whole pulled coil winding in the case of transposed conductor windings the rod connections are made through TIG inert gas shielded arc welding 13 6 2 Rotor 6 2 1 Rotor types The rotor type and the pole design depend on the machine size the speed the number of poles and the drive tasks in hand The standard variants are Synchronous motor Salient pole version Smooth core rotor laminated Solid poles Laminated poles Smooth core pole design With smooth core poles high speed motors with a relatively low mass moment of inertia can be achieved Laminated salient pole design Laminated salient poles with damper windings are primarily used for high pole motors with a mid to high range power output Solid pole design The solid pole design is mostly used for larger motors which operat
27. modified 4 5 Start up The motors are designed for a direct start up In principle re duced start up current can be achieved by e reducing the stator voltage with an autotransformer or re actance coil e frequency start up The parameters of the machine need to be quoted in all cases so that the start up conditions can be assessed including e load moment curve from idling to rated speed e mass moment of inertia e maximum permitted mains voltage breakthrough during the start up phase e number of start ups in direct sequence 4 6 Modifications e Rated voltage up to 13 8 kV e 60 Hz or other rated frequency Power factor control e Large scale and special motors for rated torques of up to 2 000 kNm Air to air hear exchanger e Start up with additional resistor in the rotor circuit for diffi cult start ups e Explosion proof version Pole design Load moment Il solid fan laminated with start up cage piston compressor 0 25 0 5 0 75 1 0 n n Ma Mn f n ny Schematic diagrams of the start up torque depending on pole design 11 5 Converter fed variable speed synchronous motors Synchronous motors with variable speed control are used in a wide variety of industrial applications Synchronous motors with a rated power output in excess of 1 MW have established themselves ahead of DC drives particularly in rolling mills on ships and in the chemical industry The advantages of synchronous machines in
28. n for any application with cus tomer specific and application orientated machines The are characterised by reliability ease of maintenance modular de sign high utilization and low noise emissions A solid design concept ensures the high level of adaptability required to be able to incorporate individual customer requirements Comprehensive know how in the factory and constant further development in collaboration with institutes and universities guarantee high quality customer specific solution The main features include e Long service life of windings with high reliable switching fre quency thanks to the use of the universal VEMoDUR insu lating system wich is backed with decades of experience e Inherent 20 thermal reserve built in tho the motors as standard e Splinter proof design of terminal boxes e Good weight to performance ratio offers improved installa tion conditions e Modular motor design ensures that spare capacity can be built into the system both easily and cost effectively e Minimal maintenance requirements particularly on variants with brushless excitation e Electromagnetic optimisation delivers high degree of utiliza tion e Excitation devices for motors without brushes ands for slipring motors supplied with automatic synchronisation and asynchronous running protection All motors are designed in a customer specific manner to fulfil the special application criteria The catalogue contains gene
29. ntains the following documents e Safety instructions e EC manufacturer s declaration Description technical data Dimensional drawing of motor e Dimensional drawing of cable connections e Connection plans for temperature monitoring anti condensation heaters e Installation assembly e Commissioning e Operation e Maintenance e Servicing e Replacement parts list e Test certificate log book e Supplemental operation manuals options third party sup pliers Any additional documentation beyond this scope must be agreed by contract The documentation is provided in two copies when the product is delivered It is available in all EU languages VEM charges for costs of additional copies additional docu mentation and translation into other languages l AL GGF GP FD FF l ais X 4 Viens cee cee T Ld Ae 1 Y 1T 11 Shipping packaging installation The type of packaging is determined at the time of contract according to the transportation and storage conditions speci fied in the order and takes into account the design and con struction of the machines VEM can offer all types of special packaging and provide shipping and installation of motors to any destination worldwide The machines are shipped either fully assembled or disassem bled depending on the size and contractual agreements VEM recommends the installation and commissioning service of our specialist personnel
30. nual e Warning and error message displays e On site controls via operator panel e Rotating diode monitoring e Controller monitoring e Rotor ground fault monitoring The exchange of signals for plant control purposes takes place digitally via the mutual provision of potential free relay contacts or relay coils The exchange of analogue signals takes place via potential free coupling blocks with standard ized current or voltage outputs Other methods for exchanging signals such as serial bus links can be modified to suit spe cific requirements 6 6 2 Excitation cabinet The excitation unit is usually laid out as a switching cabinet on static installations also as a combination of several switch ing cabinets On simple devices for low power applications other designs can also be supplied including motor attach ment wall attachment or assembly plate attachment The cab inet properties are adapted according to the specific require ments of any given application The steel control cabinet contains the entire open and closed loop excitation control systems An inspection window on the front door is available on request to provide a view of the im portant measuring instruments and displays A bottom plate Closed cooling circuit air to water with PG screw fastenings can also be supplied for the cabinet which is otherwise open at the bottom Switching devices and if applicable the power section are located on the ass
31. on circuit omission of the auxiliary excitation time constant and comparatively highly dynamic response of the control system The necessity of slip rings for transferral of the excitation cur rent the higher auxiliary power requirements and the additional expense of the excitation current actuator which is balanced by the omission of the excitation machine all need to be taken into account There are no differences between the brushless and static excitation systems in terms of open and closed loop control functions The choice of which system is used depends pri marily upon the varied requirements of the site where it is to be used although the brushless excitation system is generally the standard choice Slip ring arrangement The brush bridge consists of a brush carrier to which insulat ed brush pins with brush holders are attached The brush carrier is supported by the end plate on the ND side or it is supported by a supporting star on larger machines A slip ring body is shrink fitted to the spindle and this in turn takes the slip rings which are made of stainless steel There are branch off conductors made of round copper on the slip rings which lead to the excitation coils of the rotor 400 V 3 exciter regulator exciter and rectifier bridge mains motor firing c ARON Schematic circuit diagram sh
32. onous motors Design description Stator Rotor Rotor types Description of the design and layout Connecting boxes Bearings Cooling 72 Closed loop control D Integration into E systems Excitation cabinet Function of the excitation system Excitation Description of the design and layout of A j the excitation machine zen Start up on the converter Asynchronous low load start up Asynchronous high load start up 4 Static excitation Am Explosion proof motors Universal VEMoDUR insulation system S gt Inspections Documentation Shipping packaging and installation a General instructions E R Technical data i 7 Cover picture N Industry solutions Tree phase synchronous motors Ww a i d Foreword VEM is one of the leading European suppliers of electrical ma chines for industrial applications Our range of three phase high voltage synchronous machines is primarily used in appli cations in the chemical and petrochemical industry in steel and rolling mill technology in shipbuilding in the cement in dustry and in the manufacturing industry With this range we can offer our customers a choice of high performance drives with a global pedigree In their various design applications and different protection classes and cooling types the drives are suitable for use in piston compressors milling drives pumps fans blowers and transformers VEM can offer the right solutio
33. owing the rotor during a heavy load start up f NN pP qut NANI 7 Explosion proof motors Special regulations and directives apply to the setting up of motors in explosion hazardous areas in which dangerous concentrations of explosive atmospheres can build up The areas are divided into zones EN 60079 10 VDE 0165 part 101 IEC 60079 10 and the production tools i e the electric machines as well are divided into device categories or igni tion protection types All European manufacturers must com ply with the ATEX guidelines which became legally binding as of 1 July 2003 Depending on the conditions at the location of use Sachsen werk motors are delivered in accordance with DIN EN 50014 VDE 0170 0171 part 1 DIN EN 60079 0 IEC 60079 0 with the following types of ignition protection e increased safety e in accordance with DIN EN 50019 VDE 0170 0171 part 6 and IEC 60079 7 IEC 60079 7 on request e pressurisation p in accordance with DIN EN 50016 VDE 0170 0171 part 3 DIN EN 60079 2 IEC 60079 2 e sparkless in normal operation n in accordance with DIN EN 50021 VDE 0170 0171 part 16 DIN EN 60079 15 IEC 60079 15 Scavenging air control system EEx p The fundamental safety requirements for explosion proof mo tors in ignition protection type e as per IEC 60079 7 are in creased considerably compared to the previous design accord ing to DIN EN 50019 so that in the st
34. r synchronization has tak en place additional losses would be encountered Suitable cir cuit connections are implemented to prevent permanent connection of the start up impedance even with brushless excitation At the same time this method also achieves delib erate synchronisation This synchronisation generates a very good synchronising moment and also enables the so called crank angle control Depending on polarity the AC start up current flows either through a diode or a voltage controlled thyristor via the start up impedance in the rotor circuit whereby the series thyristor remains untriggered When the minimum slip is reached the rotor displacement angle is sensed in order to connect the excitation voltage to the excitation coil by triggering the series thyristor In the event of an overload the sufficiently high slip component of the ex citation current switches off the series thyristor allowing the motor to be re synchronised once the minimum slip is reached again 400 V 3 1 2 U ZN ZN ZN VY e eve ME LIV Y _ ZN ZX ZX X 0 1 exciter regulator 2 exciter and rectifier bridge 3 mains 4 motor Rotor circuit diagram asynchronous low load start up 6 7 5 Static excitation As an alternative to the brushless excitation method a static excitation device can also be used The advantages of this method are direct access to the exci tati
35. ral technical explanations Individ ual requirements must be treated separately The technical da ta for the basic series are also available on request from VEM We request that interested parties contact our factory sales de partment or VEM sales offices and VEM representatives Orders require our written confirmation Note We make every effort to constantly improve our products For this reason versions technical data and illustrations may be changed They are not binding until confirmed in writing by the supplying factory 1 Summary of supply 1 1 Synchronous motors with constant speed and brushless excitation Power in kW Power in kW 20 000 18 000 16 000 14 000 12 500 10 000 8 000 6 000 4 000 2 000 1 000 800 600 560 500 400 35 500 30 000 25 000 22 500 20 000 18 000 14 000 11 200 9 000 5 000 1 120 800 710 560 Voltage 6 kV Frequency 50 Hz Power factor cos q 0 9 Thermal class F utilization B 1 500 1 000 750 600 500 Speed min 4 6 8 10 12 Number of Poles Voltage 10 kV Frequency 50 Hz Power factor cos q 0 9 Thermal class F utilization B Greater numbers of poles available on request 1 500 1 000 750 600 500 Speed min 4 6 8 10 12 Number of Poles 1 2 Synchronous motors with speed control
36. s highly resistant to climate influences Rated voltage Rated surge Mains frequency Uy in kV voltage testing voltage peak value in kV effective value in kV Shaft 1 2 50 2Un 1 kV 4Uy 5 kV 6 29 13 6 6 31 14 2 10 45 21 11 49 23 13 8 60 28 6 15 65 31 VEM can also supply special designs with increased rated surge voltages on customer request Example Un 11 kV Main insulation 80 kV Winding insulation 60 kV The insulation systems is highly resisitant to climate influences i e the winding is not sensitive to humid or aggressive atmos pheres The VPI insulation system represents the standard design The technically equivalent resin rich insulating system is used on very large machines With this system resin rich mica fibre glass insulating bands are bound onto the main insulation and the winding head insulation and then hardened in the slot part under pressure and heat Within the framework of internal quality inspection in accor dance with DIN VDE electrical interim and final checks of the insulation strength are performed together with on customer request surge voltage and partial discharge level tests This ensures a quality that meets market demands and competi tive requirements The VEMoDUR insulation system is also suitable for machines with increased safety ignition protection type EExe in ac cordance with DIN EN 50019 VDE 0170 0171 part 6 as well as Exe as per IEC
37. splay unit or monitor 6 5 Cooling The machine is air cooled inside The air is either pumped axially or radially through the rotor and stator via fan wheels which are attached to the spindle self cooling or via addi tional add on fans with a motor forced ventilator In the process the air absorbs waste heat from the stamping pack and the windings The choice of cooling method depends on the overall plant project and is primarily governed by the required protection rating and the available media Standard cooling methods in clude Open cooling circuit up to protection rating IP23 Ambient air is used as cooling air Once it has cooled the ma chine it is discharged back into the atmosphere Appropriate shutters are used to ensure that the required pro tection rating is attained Closed cooling circuit with connected heat exchanger protection rating IP44 and above The cooling air inside the motor is pumped to a closed circuit primary circuit where it discharges its heat via a heat ex changer to a cooling medium secondary circuit Air to water or air to air heat exchangers are used In the case of air to water heat exchangers the pipe material used is governed by the quality of the cooling water Double pipe versions and versions with water leakage warning systems and flow monitors are also available In the case of air to air heat exchangers the outside air is AAN A NG dddd A d AA I j D
38. thin the scope of the type inspection The addition 28 al costs will be charged to the customer In this case the fol lowing inspections are conducted in addition to the individual inspection e Overspeed test e Recording of the idling characteristic curve and loss mea surement e Noise measurement at idle Wave voltage measurement on machines with insulated bearings if permitted by the construction e Degree of distortion of the voltage curve Measurement of the THF factor Reactances and time constants determination of the residual voltage Short circuit characteristic curve and loss measurement motor method Surge short circuit check Load characteristic Control characteristic Determination of the nominal excitation current Determination of the degree of efficiency Air quantity measurements pressure losses Thermal test with rated data or substitute tests Anti condensation heating Thermal time constants load limit determination Cooling time constants Runout measurement determination of the mass moment of inertia Runup measurement determination of the start up charac teristics Determination of the key variables of the synchronous ma chine Measurement of the SPM level Operating characteristic curves n f Pe cos f Pe Pmech f Pe S f Pe I f Pei prm CO En m TIR 10 Documentation Unless agreed otherwise the Operation and Service Manua documentation co
39. three phase rotating armature excitation machine with DC supply on the stator side or e athree phase excitation machine with three phase current supply on the stator side The rotor of the excitation machine supplies the excitation power to the excitation winding of the motor via rotating rec tifier modules which are connected in a three phase bridge connection 6 7 1 Description of the design and layout of the excita tion machine The excitation machine is a three phase external pole gener ator the rotor of which is mounted together with the diode bridge and protective circuitry on a hub This unit can be pulled off the spindle with minimal installation effort in terms of the excitation stator The stator of the excitation machine is supported by the end plate on the ND side or it is supported by a supporting star on larger machines The stator consists of a stamping pack made of insulated dynamo sheet round plates with stamped out poles These poles carry a DC winding If the synchronous machine is intended to be operated with a frequency controlled start up then the excitation stator is laid out with a three phase winding Salient pole rotor with excitation machine The rotor of the excitation machine is located on the rotor where it is pulled on over a bush The rotor has a stamping pack made of insulated dynamo sheet round plates with a three stranded three phase winding A 6 pulse bridge circuit rotates together with the ro
40. tor to rectify the voltage induced in the excitation rotor The output of the bridge is branched off to the excitation coil of the rotor 6 7 2 Start up on the converter The power supply to the stator winding of the synchronous motor is provided from the mains supply via a converter The latter features a complex open and closed loop controller which regulates the required output voltage of the converter according to the current operating point of the motor In addition the optimum excitation current for the excitation machine is also usually provided by the converter unit via a three phase power controller The excitation machine acts as a transformer during start up With increasing speed this mode of operation is superseded by generator operation In order to supply the voltage to the motor excitation winding there is a three phase diode bridge on the output of the rotor winding which is terminated on the DC side with a varistor or RC circuit to reduce transient voltage peaks Rotor and diode bridge of the excitation machine 21 Depending on the application the converter is only used dur ing start up In the process the power rectifier is bridged once mains synchronism is attained as a result of which the motor is run directly off the mains This means that the con verter is only called upon during start up with the correspond ing implications for dimensioning Closed loop excitation con trol is also provided by the convert
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