Industrial equipment supplier BMG’s team of electric motor designers and engineers has worked closely with global electric motor specialists to develop high-efficiency Synergy electric motors, to set the local benchmark for heavy-duty, high-efficiency motors, says BMG electric motors business unit manager Graeme Neilson.
BMG’s flagship Synergy range of asynchronous cast iron motors complies with the efficiency requirements as stipulated in SANS 60034-30:2009 and has been certified by the South African Bureau of Standards.
The Synergy three-phase asynchronous motor encompasses the latest tecnology in electric motor design and is used in many industries, including mining, water treatment, chemicals, sugar and paper milling.
BMG supplies a full range of Synergy IE3 motors ex-stock and can also supply IE4 and IE5 units from the factory, to meet exact requirements on each mine.
“Almost two-thirds of the power consumed by the mining sector is associated with electric motors. “The majority of motors on the mines are not optimised for maximum efficiency,” Neilson points out.“
Apart from energy saving – a critical issue facing Southern Africa – Synergy motors have important advantages over other electric motors. These benefits include longer service life, suitability for voltage variation applications, reduced temperature rise and minimal maintenance requirements. Synergy motors also offer reduced noise and vibration levels, higher reliability, greater flexibility and lower cost of operation.”
Synergy IE3 motors incorporate high-level specifications and features, including an oversized terminal box with a removable gland plate, for easy replacement of the cables. Motors from frame size 80 to 132 have sealed bearings and all motors 160 frame and above have regreaseable bearings. The standard lubrication nipples are manufactured from brass or stainless steel material and are suitable for all environments.
These motors have a rated voltage of 400 V and 525 V and a rated frequency of 50 Hz. The efficiency and power factor values ensure cost efficiency, with a return on the investment of between three and five years.
Synergy motors are most efficient when running between 75% and 100% of full load, emphasises Neilson.
An electronic soft starter ensures the starting sequence is efficiently controlled. Standard motors operate at fixed speed, regardless of the actual output required, while Synergy motors can operate efficiently without cogging at low speed, in conjunction with a variable-speed drive (VSD), reducing energy consumption by over 50%. VSDs enable the speed of the motor to be controlled to achieve maximum efficiency at the required load.
The Synergy IE3 motor has undergone surface treatment to ensure extended service life in harsh conditions. The latest design allows the terminal box to be mounted top, right or left and the cable entry can be rotated 360º, without disassembling the motor.
Synergy has also developed aluminium housing motors, with cast iron end shields, for frame sizes up to 180.