APPLICATION otes
N
Published for the Basler Electric Power Systems Group
Synchronous motor controller prevents pole slip and
saves costs when operating brushless synchronous motors
Many brushless synchronous motors use a fixed dc
power supply for excitation, a low cost solution that
works reasonably well if motor loads and the power
supply voltage remain relatively constant. If motor load
varies widely, or if the power supply voltage is subject
to significant drops, such as those that occur when
other nearby motors are started, a constant excitation
source may be unable to maintain the motor in syn-
chronism, resulting in pole slip and asynchronous
operation. Pole slip events can seriously damage
components of the motors brushless excitation system,
and asynchronous operation can quickly cause motors
to overheat.
During pole slip events, large currents are induced
in the field flow in opposition to the normal direction
of excitation current, which creates voltage transients
that may exceed the peak inverse voltage rating of the
power semiconductors on the rotating rectifier. If the
semiconductors fail, the remaining semiconductors in
the circuit must operate under overload conditions
until the rotating bridge can be repaired.
Using a fixed source of excitation also eliminates
the possibility of using the motors to provide local Var
support or to assist in controlling power factor on the
supply bus. Poor power factor can cause excessive
loading on transformers and cabling and usually results
in higher than necessary power bills. Proper operation
of synchronous machines can provide significant
savings in power cost for a relatively small investment
in improved motor controls. (See Figure 3.)
Both of these potential problems can be addressed
by replacing fixed dc motor exciters with excitation
control systems that automatically maintain adequate
excitation to the motor to prevent pole slip during load
or power supply transients, while providing a means to
optimize Var production by the motor during normal
operation.
Basler synchronous motor controller
The brushless synchronous motor control system
shown in Figure 2 provides the required automatic
control for brushless motors. The MVC (manual
voltage control) provides a reliable source of field
current interface with the SCP 250 Var/PF controller to
provide the means to automatically respond to voltage
#125 August 1997
transients, as
well as provide
a reliable
means for
controlling the
Var output or
power factor of
the motor
during normal
operation.
Var operation
versus power
factor control
The use of
Var mode Figure 1: Synchronous Motor
versus power
factor operation is application dependent. For constant
loads, power factor operation is the preferred operating
mode of the synchronous motor. Likewise for applica-
tions such as ball mill grinders or chipper motors, Var
control may be the favored control. The nature of these
loads is cyclic, which produces momentary power load
surges in the system. Here, if the system operates in
power factor mode, the power surges will be sensed and
cause the excitation system to produce cyclic surges of
field power in response to the load. This will result in
the power factor meter appearing unstable in response
to the nature of the load. For these applications, Var
control provides the best solution . Here, the power
component is not sensed by the controller, so the
system provides smooth, stable operation for the motor.
Motor protection
The controller includes field over and under
current and motor pullout protection and an adjustable
incomplete sequence timer that can be used to initiate
motor loading when the motor has been successfully
synchronized.
The field current relay monitors excessive or
insufficient field current that can be caused by motor
overload or too low a level of excitation current caused
by component failure or improper adjustment. (See
Figure 4.)
Notes:
1 Item not supplied by Basler.
Figure 2: Brushless Synchronous Motor Control Excitation System
Operation
The excitation system (See Figure 2.) is enabled via
the remote start/stop contact, which is generally closed
when the main motor breaker closes. Once enabled, the
K1 on/off relay closes and applies power to the manual
voltage control input. The manual control receives an
input from the Var/PF controller to automatically adjust
field excitation to the motor. Placing the S2 switch in
the manual position provides constant field excitation,
without automatic control. When placed in Var position,
the Var/PF controller is enabled and will maintain either
constant Vars or constant power factor.
S1 is used to calibrate the manual control to inter-
face with the Var/PF controller.
If excitation is not applied within time defined by
K2 (incomplete sequence timer) while the motor is
being started, an alarm output will provide annuncia-
tion that the unit has not synchronized. Protective relays
that include under and over field current monitor the
motor field current level and motor pullout. They are
used to determine if the machine is operating within
the acceptable limits of the design. Contacts for these
relays are wired out to a single alarm output.
External Monitoring of
Brushless Exciter Diodes
An optional exciter diode monitor can be added to
the system to monitor the output of the brushless
exciter. The EDM200 is mounted in a location that is
external from the synchronous motor controller, and
monitors the field current for changes in ripple fre-
quency. When a diode failure occurs, the ripple fre-
quency will decrease, providing a unit alarm.
Remote Var Management
The synchronous motor controller can be inter-
faced with an RA-70 Reference Adjuster and a 4-20 ma
input. The 4-20 ma input can be used in conjunction
with an energy management system to optimize Var
flow from the synchronous motor to reduce energy cost
within a plant. Reduced Var consumption can be
realized by overexciting the synchronous motor to
correct for magnetizing losses caused by inductive
loads. A power measuring energy management system
can automatically vary the amount of Var flow via the
synchronous motor controller to optimize the plants
energy usage and reduce Var cost.
Applicable to dc Exciters
Although most of the information described relates
to the brushless exciter, the synchronous motor control-
ler may also be used for dc exciters. Here, the brushless
exciter is replaced with a dc exciter rotating having
commutators and brushes. The dc field breaker and
starting resistor (not shown) is used for starting the
synchronous motor. Once the motor speed reaches
synchronous speed, the excitation is applied.
In some applications, the dc exciter is replaced with
a static exciter. The power for the main field is derived
from power semiconductors rated for its main field
requirements. All control is static via silicon control
rectifiers.
For more information, consult the Basler factory at
618/654-2341 or visit our web site at http://
www.basler.com.

Type of Conditions Motor Synchronous Affect on Economics

Excitation System Field Excitation Motor Operation System

Fixed dc supply - Low Bus Under excitation Lagging - Increase Costs

voltage power factor KVA
- Excessive loading on
load on plant
motor transformer
- Reduce
system
voltage
- Potential
pole slip

Automatic controller Automatic Leading - Decrease Saves

power factor power factor KVA
correction loading of
plant
transformer
- Improves
voltage
stability of
Bus

Figure 3: Synchronous Motor Operation, Lagging versus Leading due to Abnormal Operating Conditions
 Models Field Current Field Voltage Sensing Input Var Control Power Factor
Amp. Voltage Current Range Range

SMC-36 0-36 Amp 32 120 Vac 3-5 Amps 0-100% Var .55 to 1.0 Lead
63
SMC-7 0-7 Amp 125 Lead or Lag .55 to 1.0 Lag

Incomplete Sequence Motor Pullout Field Undercurrent Field Overcurrent

Adjustment Range Range Time Range Time Delay Range Time Delay
Time

0 - 30 seconds .95 - .8 .25 - 1.5 40-100% 0 100-120% .4-10

PF lag Seconds Seconds Seconds

Figure 4: Synchronous Motor Controller Data Sheet

ROUTE 143, BOX 269, HIGHLAND, ILLINOIS U.S.A. 62249 P.A.E. Les Pins, 67319 Wasselonne Cedex FRANCE
PHONE 618-654-2341 FAX 618-654-2351 PHONE (33-3-88) 87-1010 FAX (33-3-88) 87-0808
http://www.basler.com, info@basler.com

APNOTE125 (8/97)