Pioneer Electrical Works, started manufacturing

Back Panel Heading

slipring motor starters, in a modest way, in 1967.
Nearely a quarter century later, PIONEER has for the first time in india, manufactured 5000 kW
liquid resistance slip ring motor rheostats.

Liquid Resistance
Rheostats typeLRS
Pioneer Electrical Works

Products developed at PIONEER must represent genuine technical advance. Due to this philosophy no challenge has been too great for PIONEER, and like a David, we have always risen to
challenges however Goliath in size or complexity be the drive to be controlled.
This brochure gives you details of our range of liquid resistance rheostats type LRS, however, it
is not meant as a substitute for a personal meeting. It is intended to set the stage to create an
interest in our products, leading to personal interaction, thereby enabling us to extend to you
the pre and post engineering services, which are the hallmark of PIONEER.
Not only are high quality competitive range of products offered by PIONEER, but out traditional
strengths are the engineering services that back our products.

Pioneer Electrical Works

1, R.K. Industrial House,
Walbhat Rd, Goregaon (E),
Mumbai - 400 063

Micro-Watts controls Mega-Watts

Phone: +91-222-685-3634
Fax: +91-222-685-3216
E-mail: info@pew-india.in

Introduction:
The range of PIONEER liquid rheostats - type LRS - is designed for controlling of large KW slipring motors and extends, upto 5,000 kW, or any higher rating required.
PIONEER type LRS rheostats unique design, with horizontal movement of the moving contact system, enable a wide variation of the resistance. This coupled with current sensing
relay which synchronises the change of resistance to the motor acceleration, ensures smooth progressive acceleration of the drive.
With the use of Computer Aided System Engineering (CASE), wide range of specific requirements can be created to including twin drive rheostats for large drives and speed variation by control slip.
PIONEER type LRS rheostats incorporate:
-Tank for electrolyte - available in dicrete frame sizes, according to KW rating,
- Horizontal movement contact system, and
- Control panel,
All mounted on a common frame.

Introduction:

Electrolyte Tank

The control system is housed in a control panel constructed out of sheet and having ingress protection IP53/54.

The tank for the electrolyte is of welded construction, made from mild steel of adequate thickness and strengthened by gussets where needed. The inner surface of the tank is lined with FRP to provide greater corrosion resistance.

The pilot motor drive of the moving contact system control by forward-reverse starter. An electronic current relay senses the
drive motors stator current and synchronises the displacement of the moving contact system and hence the resistance of the
moving contact system and hence the resistance variation to the acceleration of the motor.

The tank can be filled from the top and drained through a drain plug provided at the bottom of the tank. Level guage, with over flow
spout, is provided for visual indication of the electrolyte level.

Rheostat System
Three stainless steel electrodes, mounted on a channel to form star point, move on two parallel guide rails between the stainless
steel fixed electrodes. The fixed electrodes are connected by copper bus through porcelain
bushes to the rotor terminals. The area
of the electrode system plates are designed for low current density of 1 amps/cm 2
A 0.25 kW, servo motor coupled by a worm reducer to a chain and sprocket arrangement moves the electrode carriage on the
horizontal guide rails. The servo motor is coupled through a clutch arrangement which enables emergency manual operation of
the electrode carriage by hand wheel provided or this purpose.
On completion of the contact carriage system are signaled by oil tight limit switches, which also serve to interlock the carriage
movement so that it remains in the resistance shorted position, so long as the controlled motor is operating, and returns carriage
corresponding to greatest resistance position, when motor is switched off.
Polyproplene barriers between phase fixed to one end of the tank, increase insulation levels and reduce cross currents. The other
end of the barrier being free allows circulation of liquid to maintain temperature and concentration of electrolyte uniform.
Adequately diamensioned cable box houses the rotor terminals which can conventionally accept two or three runs of cable
terminated on L shaped tinned copper terminal.

Control System:

A supervisory timer is provided to switch off the main motor in case the starting time is
abnormally prolonged. Low level indication and interlock with main motor starting are
also provided. Optional control equipment can also be incorporated on request.
SPECIAL APPLICATIONS
TWIN DRIVE RHEOSTATS type LRS x 2
When the drive mechanism requires large KW then to reduce mechanical stress it may,
sometimes, be preferable to provide two motors totaling the KW required rather than a
single motor.
A twin drive rheostat is then indicated. The PIONEER type LRS x 2 rheostat ensures
identical acceleration of both motors. The moving carriages are mechanically coupled and
driven by single servo mounted on common frame are used. In this case the ohmic resistances of the electrolyte of the two tanks are equalized through interconnections between
the two tanks.
MOVING ELECTROLYTE RESISTANCE RHEOSTAT-type MERS
For very large drives PIONEER offers the moving electrolyte resistance rheostats. These
rheostats are available for both single and twin drives.
Type MERS starters incorporate cylindrical mid steel tank fitted with conical electrode-

serving as the LOAD CELL connected to reservoir tank through a pump. Bye-pass valves
allow variation of the time of displacement of the electrolyte and hence the rate of change
of resistance, thus enabling optimizing of the resistance change to give a very smooth acceleration.
LIQUID SPEED REGULATORS-type LSR
When speed regulation is required this can be obtained by permanent slip resistance. In
this case the heat generation in the electrolyte increases and it is then necessary to provide
heat exchanger to increase the heat dissipation capacity of the speed regulator. PIONEERS speed regulators incorporate heat exchangers.
PIONEERS SMOOTH START
PIONEER type LRS liquid resistance starters, with high ratio of starting resistance to resistance at shorting, coupled with stepless variation of the liquid resistance synchronized
with motor acceleration provides a very smooth start.
Accompanying figure shows some comparative methods of starting, which clearly illustrates the advantages of PIONEER LRS rheostats.

COMPARISON OF PIONEERS HORIZONTAL ELECTRODE CARRIAGE MOVEMENT SYSTEM WITH VERTICAL ELECTRODE MOVEMENT OR SECTORAL CLECTRODE MOVEMENT.

HORIZONTAL ELECTRODE MOVEMENT

The carriage system being support on horizontal rails and
movement being on rollers the wear and tear, even in
harsh environmental conditions, due to gravitational
forces is negligible.
Construction is such that there is no chance of electrode
breaking form carriage system and dropping.
Both the fixed and moving electrode are well below the
top level of the electrolyte, and with easy circulation of
the electrolyte the resistance is uniform. Starting torque
always remains constant.
Current relays synchnise displacement of resistance to
motor acceleration for smooth start.

VERTICAL ELECTRODE MOVEMENT

Gravitational load acts on the guide bar and
screw, which in presence of dust particles, typical in cement plants, sugar plants, and steel mills quickly wears
out the screw. Resulthigh maintenance frequent downtime.
If the nut breaks the electrode will instantly drop to min.
level. This could be dangerous.
The electrode movement starts from the top. After some
time of running electrolyte heats up and the upper layer
being hotter has lower resistance. Thus, on repeat starts,
starting torque can very.
No current relay provided hence, no synchronization of
resistance displacement to motor acceleration.

SECTORAL ELECTRODE MOVEMENT

In sectoral system of movement of electrodes the warm
and gears wear out fast in the presence of dust with the
action of gravitational forces. Result high maintenance
and frequent down time.
If the worm breaks the electrode will drop to minimum
level. This could be dangerous.
After some running electrolyte gets hot, its resistance
reduces. Electrode movement starting from top, the starting torque is likely to vary on repeat starts.
No current relay, hence no synchronization of resistance
displacement to motor acceleration.