Synchronous Motor Digital Control & Monitoring Systems  - KinetSync Kinetics Industries, Inc.
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Synchronous Motor Field Excitation Systems PDF

Cranes Metal Manufacturing Metal Magnetic Cranes Water Plant Crane Water Pumps

Brush Type Synchronous Motors
Complete Integrated Excitation System

ISO 9000:2015
Kinetics Industries, Inc.
The Kinetics model type ESR is a product designation for a excitation system that contains, as a minimum, an exciter and a solid state field application circuitry.

The Kinetics model type ESR is a product designation for a excitation system that contains, as a minimum, an exciter and a solid state field application circuitry. A typical ESR system would include a Kinetics’ SVR rectifier, SynchApp-SS application circuit and KinetSync-SR digital logic and annunciation module.

Kinetics Industries is the only manufacturer in the United States to design and manufacture the critical segments required for a brush type motor excitation system as a single source manufacturer. Kinetics has the in-house design and manufacturing capacity to:

  • Fabricate enclosures and/or panels.
  • Transformers manufactured up to 2500 KVA and 15 KV class.
  • Electronic circuitry.
  • Power semi-conductor assemblies and associated firing circuits.
  • Software logic, control and annunciation.
  • Unit testing using a synchronous motor.
Kinetics Industries Integrated Excitation

One source responsibility for an excitation system is our goal. Kinetics products are designed specifically for synchronous motors. Our units are not an adaptation or function compromise using components designed for another type of machine, such a generator or motor drive. Synchronous motors and the processes they drive, have specific needs that Kinetics has incorporated into the product we manufacture.

We are flexible! Kinetics can manufacture a complete system but we are willing to work with a customer to use existing component sections, components provided by "other" or components sections manufactured by a competing product (SPM).


The primary segments of a Kinetics designed & manufactured excitation system are:

  • Primary disconnect – fusing panels or circuit breaker.
  • EPT – exciter power transformer.
  • DC field exciter – regulated or non-regulated output.
  • Field application panel – solid state switching or DC contactors.
  • KinetSync-SR digital annunciation and logic controller
  • Discharge resistor grid.
  • Stand alone enclosure or open panels for mounting by other.

The ESR, synchronous motor field application system is a state-of-the-art system that provides continuous, confirmed motor and excitation system operational status, protection and control. The ESR consists of an integrated regulated exciter rectifier and a 100% solid state synchronous motor field application panel. The ESR system incorporates solid state sensing of the motor field characteristics, digital logic sequencing control and protection, regulated solid state rectification with a motor field and discharge resistor engaging and disengaging by means of Kinetics’ high peak reverse voltage blocking capacity semi-conductor switching package that includes crowbar protection sequencing protection to assure application of the field discharge resistors.

Kinetics’ philosophies of design and manufacturing are applied in every Kinetics ERS excitation system. We strive to design and manufacture a product that is low in maintenance, conservatively rated, interactive with the production system and provides annunciation and diagnostic feedback that helps to minimize troubleshooting downtown.

Maximum motor protection is a critical product goal. The Kinetics ESR system is a "confirmed motor status" operating system. The motor line voltage, stator current, motor power factor, exciter field voltage & current and field discharge resistors are continuously monitored for confirmed proof of the motor and excitation system is in a "correct" operational status. Inter-locking and overlapping protection features provide for maximum motor and power system protection. At no time does the system have "blind" spots of operation or is the field applied with the assumption that the motor has reached synchronous pull-up speed.

Kinetics Industries Integrated Excitation

The motor field current is monitored throughout the starting, running and shutdown sequences to provide continuous sequence and operational protection and motor operating status annunciation. The Kinetics KinetSync-SR includes a history / date stamp registry that records events, dates and times that caused a "trip" taking the motor off-line.

A focus point feature of the Kinetics field application system is the "impending pullout of synchronization protection". By using signals from the AC motor starter CT’s and PT’s, Kinetics’ field application logic circuitry senses that the motor is pulling out of synchronization and shuts the motor down, by tripping the motor starter off line, before the motor is pulled out of synchronization. Pulling out of synchronization, while the motor is under load, can cause damage to the motor and produces significant power system disruption.

The ESR excitation package is designed to operate in conjunction with the AC motor starter using control signals from the starter CT’s & PT’s. The rider signal burden required by the Kinetics system to the CT’s & PT’s is negligible. Kinetics can provide a motor starter with the excitation system as an available option.

An integral part of the ESR system is the highly reliable, field proven, Kinetics SVR regulated excitation rectifier that is designed and rated for the highly inductive load operating parameters of the synchronous motor field excitation. The output of the SVR exciter can have the regulation feedback loop closed on either field current, field voltage, motor power factor, VAR’s or a remotely supplied signal by "other". The mode of output regulation must be selected at time of order. For a detailed specification on the rectifier section of the ESR see the description for the SVR model types.

The Kinetics SynchApp-SS is the section of a field application system that assures that the excitation power is applied to the motor field at the correct time and the field discharge path is applied or removed when required. The Kinetics system incorporates a redundant configuration of both a solid state SCR switching package and a semi-conductor crowbar circuit. An avalanche diode circuit, often referred to as a "crowbar circuit" is provided on the field discharge circuit SCRs as a backup to the controlled electronic discharge SCR triggers. This circuit, figuratively, converts the discharge SCRs into diodes when operative. The crowbar functions if the voltage across the field discharge path exceeds the avalanche point of the avalanche diode (Zener diodes) without an electronic trigger circuitry power. The avalanche or "crowbar" level is selected to be above the maximum peak voltage from the rectifier and below the peak inverse rating, PRV, of the power semi-conductors and well below the safe dielectric level of the motor field insulation. The Kinetics SynchApp-SS system assures that the discharge path is effectively closed even in a powered down condition.

The operating center of the Kinetics ESR system is Kinetics’ KinetSync-SR digital annunciation and logic controller module. The robustly designed and manufactured KinetSync-SR module is a digital logic, micro-processor based, state-of-the-art industrial control module that continuously monitors the systems operational functions. The unit provides continuous readout of the systems operational status during the start-up sequence, run and the shutdown sequence. The unit includes a detailed "trip" history registry and date stamp function for assistance in servicing and maintenance to the motor, motor starter and / or excitation system.

Amortisseur or squirrel cage winding service factor protection is provided by a "dwell time lockout" the prevents damage to the motor from immediate attempted motor re-start as a standard feature. The dwell time interval is adjustable through the operator keypad of the KinetSync-SR module.
The KinetSync-SR provides the following protection and features:

  • Continuous monitoring of motor and field excitation system.
  • Assurance of field discharge path.
  • Motor start incomplete sequence protection.
  • Field loss protection.
  • Motor pull-out-of-synchronization protection
  • Locked rotor protection.
  • Control voltage signal for field application at the proper speed and phase angle.
  • Unit includes a ready to use RS232 communications port.
  • Touch pad parameter of operation operator adjustment.
  • Security code protection by touch pad operation.
  • Power factor monitoring and vernier signal for interfacing with a regulated field exciter.
  • Motor dwell time lockout function.
  • Back lit LCD annunciation screen for continuous display of motor field amps, field volts, power factor and motor operational status.
  • System "problem" flashing LED annunciation.
  • LCD screen displays cause of "fault" or system "problems"
  • Trip history registry and date stamp.
  • Laptop computer accessible through the RS232 interface port.
  • UL and ULC listed product

Interconnect cables: From our years of working with industrial, utility and OEM customers, a common concern of installers and maintenance people alike, is to install component sections as quickly as possible and minimize the possibility for interconnection wiring errors. Kinetics is the only manufacturer to offer factory manufactured, electro-statically shielded, interconnection cables with heavy industrial Molex plugs for use with our KinetSync-SR unit to the SynchApp-SS exciter / field application panel.

System testing: Kinetics’ factory test stand includes a synchronous motor. All Kinetics manufactured excitation systems are tested via the brush type synchronous motor within our testing facility.

Kinetics excitation system optional features: (Partial list)

  • Field forcing – common to rolling mills
  • Motor inching control – common to ball & bar grinding mills
  • Redundant / parallel system or features.
  • Remote operation and annunciation for un-manned motor rooms or facilities.
  • Synchronous condenser operation.
  • Non-standard voltages.
  • "Low" RPM machines with "large" field current values.
  • Application environmental demands such as "high" elevations or elevated operating environments.
  • AC motor starter.
  • Kinetics factory start-up engineer for unit commission and training.
  • Units manufactured and tested to CSA or UE standards.

Information needed for a proposal:

  • Is a system section or an entire system required?
  • Industry / application of the motor / type of load.
  • Motor horsepower, line voltage, field volts, field current.
  • AC input voltage available for the exciter.
  • Discharge resistance value specified by the motor manufacturer.
  • Starting acceleration time to pull-up speed.
  • Motor starter relay coil type, AC or DC.
  • Enclosure, cell-in-cell or open panel packaging.
  • Is it desirable to place operational information / data onto a communication network such as SCADA or MOD BUS?
  • Application specific requests.

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