Direct on line

The DOL starter power circuit consists of following devices all connected in series. Short circuit protective device -SCPD(Switch fuse disconnector) or MCCB Power contactor Overload relay To start the motor, the SCPD is closed and the start command is given through start P.B. Control circuit for DOL: The coil of contactor gets supply through the interlocks in the control circuit. The proper operation of DOL starter mainly depends upon the pick-up and drop-off of the contactor. The indications for the starter are given according to the power contactor status (ON/OFF) and the fault indication through the relay DOL method is the direct connection of the motor terminals to the supply terminals through a suitable starter having contactors operated by a coil. This method is restricted to small motors below 5 hp (3.75 kW). Otherwise reduced-voltage starters are employed with motors above 5 hp. DLO method causes a high starting current at a lagging power factor. It also can causes voltage fluctuation on the supply network. DOL starting is sometimes used to start small water pumps, compressors, fans and conveyor belts. In the case of an asynchronous motor, such as the 3-Phase Squirrel-Cage Motor, the motor will pull a high starting current until it has run up to full speed. This starting current is commonly around 6 times the full load current, but may as high as 12 times the full load current. Overload coil - Also known as the thermal overload is responsible for opening the starting circuit and cutting the power supply to the motor in the event of the motor drawing too much current from the main supply. The thermal overload consists of a heating device which increases in temperature with the running current, and a bimetallic strip located near the heating device which can deflect and mechanically trip the device and open the circuit. The heater coil and the action on the bimetallic strip introduces a time delay, which allows the motor to tolerate the brief high starting current and to settle in to a normal running current, while protecting it from a running current overload. No volt coil - The no volt coil keeps the hold-in contactor closed and ensures power flow across the control circuit. When the start switch is initiated, the no volt coil is energized and it attracts and keeps the hold-in contact closed. In the event of no power being supplied to the motor, the no volt coil is deenergized and releases the hold-in contact. This ensures that the current flows in the control circuit only when the no volt coil is energized. Short comings of the DOL starter The DOL starter attracts high current. Therefore, it may be inconvenient to the other users of the supply line since whenever a motor with a DOL starter is turned on, they will experience a voltage drop. DOL starter also provides a very high starting torque. This can be a strain on the driven load. The high starting torque may cause mechanical wear on the components connected to the load. Because of these reasons, the DOL starter can be used for only low power or more specifically stated, motors with a rating of less than 5KW

Star Delta starter

This is a starting method that reduces the starting current and the starting torque. The components normally consist of three contactors, an overload relay and a timer for setting the time in the star position. The motor must be delta connected during a normal run, in order to be able to use this starting method. The received starting current is about 30% of the starting current during direct on line start and the starting torque is reduced to about 25% of the torque available at a DOL start. This starting method only works when the application is light loaded. A two-position switch (manual or automatic) is provided through a timing relay. Starting in star reduces the starting current. When the motor has accelerated up to speed and the current is reduced to its normal value, the starter is moved to run position with the windings now connected in delta. More complicated than the DOL starter, a motor with a star-delta starter may not produce sufficient torque to start against full load, so output is reduced in the start position. The motors are thus normally started under a light load condition. Switching causes a transient current which may have peak values in excess of those with DOL.

Operation In operation, the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially, and then after a period of time, the star contactor is opened, and then the delta contactor (KM2) is closed. The control of the contactors is by the timer (K1T) built into the starter. The Star and Delta are electrically interlocked and preferably mechanically interlocked as well.

In effect, there are four states 1. OFF State. All Contactors are open 2. Star State. The Main and the Star contactors are closed and the delta contactor is open. The motor is connected in star and will produce one third of DOL torque at one third of DOL current. 3. Open State. The Main contactor is closed and the Delta and Star contactors are open. There is voltage on one end of the motor windings, but the other end is open so no current can flow. The motor has a spinning rotor and behaves like a generator. 4. Delta State. The Main and the Delta contactors are closed. The Star contactor is open. The motor is connected to full line voltage and full power and torque are available.

This type of operation is called open transition switching because there is an open state between the star state and the delta state.

Autotransformer starter

motor, which can be connected permanently in delta or in star, is switched first on reduced voltage from a 3-phase tapped auto -transformer and when it has accelerated sufficiently, it is switched to the running (full voltage) position. The principle is similar to star/delta starting and has similar limitations. The advantage of the method is that the current and torque can be adjusted to the required value, by taking the correct tapping on the autotransformer. This method is more expensive because of the additional autotransformer. There are two ways of connecting an auto transformer starter, the most obvious way is to apply full voltage to the transformer via a contactor, and connect the motor to the tap by means of a contactor. When the motor has accelerated to full speed, or has run out of acceleration torque, the tap contactor opens, disconnecting the motor from the transformer and another contactor closes connecting the motor to the supply. The transformer can now be disconnected from the supply. This format is known as an open transition starter and is less than ideal due to the fact that the motor is disconnected for a short period of time during the start period. While the motor is connected and accelerating, there is a rotating magnetic field in the stator which causes flux in the rotor and thus a rotor current to flow. At the instant the motor is disconnected, there is a magnetic field in the rotor which is spinning with-in the stator winding. The motor acts as a generator until the rotor field decays. The voltage generated by the motor is not synchronized to the supply; and so on reconnection to the supply, the voltage across the contactor at closure can be as much as twice the supply voltage resulting in a very high current and torque transient. This open transition switching is often known as the auto-reclose effect as it yields similar characteristics to opening and closing a breaker on a supply to one or more motors. The consequences of open transition switching can be as bad as broken shafts and stripped gears.

Rotor resistance starting

The method used for squirrel cage motors can also be employed for starting wound rotor motor , but it is usually not done because then the advantages of wound rotor motor cannot be realized. The simplest and cheapest method of starting wound rotor induction motor is by means of added rotor resistance, with full line voltage across the stator terminals. The addition of external resistance would,

decrease its starting current increases its starting torque improves its starting power factor

By adding eternal resistance to the rotor circuit any starting torque up to the maximum torque can be achieved; and by gradually cutting out the resistance a high torque can be maintained throughout the starting period. The added resistance also reduces the starting current, so that a starting torque in the range of 2 to 2.5 times the full load torque can be obtained at a starting current of 1 to 1.5 times the full load current. In a slip-ring (wound rotor) induction motor, resistance can be inserted in the rotor circuit via slip rings, so as to increase the starting torque. The starting current in the rotor winding is

Where Rext = Additional resistance per phase in the rotor circuit The input (stator) current is proportional to the rotor current as shown earlier. The starting current (input) reduces, as resistance is inserted in the rotor circuit. But the starting torque increases, as the total resistance in the rotor circuit is increased. Though the starting current decreases, the total resistance increases, thus resulting in increase of starting torque and also obtained by using the expression given earlier, for increasing values of the resistance in the rotor circuit. If the additional resistance is used only for starting, being rated for intermittent duty, the resistance is to be decreased in steps, as the motor speed increases. Finally, the external resistance is to be completely cut out, i.e. to be made equal to zero (0.0), thus leaving the slip-rings short-circuited. Here, also the additional cost of the external resistance with intermittent rating is to be incurred, which results in decrease of starting current, along with increase of starting torque, both being advantageous. Also it may be noted that the cost of a slip-ring induction is higher than that of IM with cage rotor, having same power rating.

To select the values of the resistors, you need to know the frame voltage and the short circuit current. The maximum torque occurs approximately at the point where the rotor reactance equals the termination resistance. The final stage of the resistance should always be designed for a maximum torque close to full speed to prevent a very large step in current when shorting the final stage of resistance. If a single stage was used and the maximum torque occurred at 50% speed, then motor may accelerate to 60% speed, depending on the load. If the rotor was shorted at this speed, the motor would draw a very high current (typically around 1400% FLC) and produce very little torque, and would most probably stall.

Power electronic starters (soft starters)

The soft starter controls the voltage without steps from a selectable starting value up to 100 per cent. This continuously increases the torque and also the current. This means that the soft starter enables loaded motors to be started smoothly, without the steps associated with electro-mechanical starters. The soft starter employs solid state devices to control the current flow and therefore the voltage applied to the motor. In theory, soft starters can be connected in series with the line voltage applied to the motor, or can be connected inside the delta loop of a delta connected motor, controlling the voltage applied to each winding.

1 x Triac per phase

1 x SCR and 1 x Diode reverse parallel connected per phase.

2 x SCRs reverse parallel connected per phase.

The phase control is implemented in all three phases. Two back-to-back thyristors are used as power semiconductors. This means that the phase voltage is controlled in both half waves (full wave control). As a result of the upper harmonics occurring during phase control, the motor is nevertheless put under a higher thermal load than during a direct start.

Advantages of soft starters: 1. 2. 3. 4. 5. 6. 7. Increased acceleration time can be beneficial for motor and machine. The starting current is reduced or can be limited. The torque is adapted to the corresponding load. For pumps, surges during start and stop can be avoided. Jerky movements and shocks, which could hamper a process, are avoided. The wear and tear of belts, chains, gears and bearings is avoided. By means of the different controls, simplified automation is possible.