E&S - Tony Narusevicius - 20-09-2005 - English 1

Which MV motor starter

to choose?
E&S - Tony Narusevicius - 20-09-2005 - English 2
The MV starter and motor are the links between the
electrical network and the mechanical load
Load Motor
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starter
E&S - Tony Narusevicius - 20-09-2005 - English 3
The motor starter must be designed to limit the
constraints to the network, the motor and the load
The type of motor starter will influence
the perturbations on the network
the mechanical strength to the mechanical load
the starting torque on the shaft

The protection will protect the motor
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Overcurrent
Thermal (It) rotor
Thermal (Pt100) stator
Protection
Load Motor
E&S - Tony Narusevicius - 20-09-2005 - English 4
The network has constraints
Acceptable inrush current

Acceptable starting undervoltage

Acceptable power factor

short circuit withstand

Acceptable harmonics

E&S - Tony Narusevicius - 20-09-2005 - English 5
The load has constraints
Resistant torque curve

Starting inertia

Acceptable mechanical stress

operating conditions
Starting time
number of starts
automatic starting
operating cycle
overload
locked rotor current
deceleration control
........
E&S - Tony Narusevicius - 20-09-2005 - English 6
The motor-starter must be designed to control,
protect and supervise the motor for maintenance
Motor control: local or remote; automation....

Electrical motor protection
short circuit
under-voltage
........
Preventive protection
temperature through thermal image or sensors
bearing vibration sensors
moisture
derating for altitude
.........
The design of the motor starter should decrease the number
of spare parts....
.........

E&S - Tony Narusevicius - 20-09-2005 - English 7
The most common motor: asynchronous motor
the 3 windings of the stator are placed at 120 and
are fed by the service voltage
these 3 coils create a rotating magnetic field around
the axis of the stator
this magnetic field creates a current in the rotor
the rotation of the rotor N is lightly slower as the
magnetic field one Ns


There are 2 types of asynchronous motors
single or double cage motors (rotor is short
circuited)
slip ring rotor motor (resistance of the rotor can
be modified by introducing external resistances)
phase 1
phase 2
phase 3
120
E&S - Tony Narusevicius - 20-09-2005 - English 8
Influence of the service voltage on the motor torque
N (speed) Ns
starting torque
V"s > V's
Vs
V's >Vs
Torque
acceleration torque
The lower the voltage; the lower the motor torque
If the motor torque is lower than the resistant torque the motor does not start
E&S - Tony Narusevicius - 20-09-2005 - English 9
Asynchronous motor
single cage rotor
double cage
deep slot rotor motor
starting torque
low
from 0.6 to 1 Tr
slightly higher
from 0.8 to 1.2 Tr
maximum torque
around 2 to 2.2 Tr
around 2 to 2.2 Tr
(slightly higher for deep slots)
starting current
from 4.5 to 5.5 Ir from 5 to 6.5 Ir
these motors are ideal for intensive use and hazardous environments
excellent mechanical and
electrical robustness
simplicity of design
no brushes
relatively low power factor 0.8
to 0.9 on full load
if asynchronous installed
motor power is high reactive,
power compensation may be
required
E&S - Tony Narusevicius - 20-09-2005 - English 1
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Asynchronous slip ring rotor motor
the impedance of the rotor winding can be modified by introducing
external resistances.
by decreasing external resistance on starting (from Rr" to R), the
characteristic of the torque is translated and the starting torque
adapted to the torque of the machine.
T
N
Ts
T max
T load
R= rotor resistance
Rr >
Rr ' >
E&S - Tony Narusevicius - 20-09-2005 - English 1
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Synchronous motor
The main differences with asynchronous motors are:
their constant speed (synchronous speed)
the rotor circuit supplied with Dc
the power factor which may be set by the exciting current

In a conventional synchronous motor controller
the DC power is applied from an external source
brushes and slip rings carry the current to the field winding

A brushless synchronous motor
it generates its own DC power for its field
the amount of DC power is controlled through induction
low current DC power applied from the controller
E&S - Tony Narusevicius - 20-09-2005 - English 1
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Load torque curves of machines
compressor
E&S - Tony Narusevicius - 20-09-2005 - English 1
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Starting conditions:
motor torque must always be greater than the load torque
the motor starts
the motor does not start
running point
E&S - Tony Narusevicius - 20-09-2005 - English 1
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Some of the different types of MV motor
starter
Full voltage on the stator or direct on line
FVNR or DOL

Reduced Voltage through reactance

Reduced Voltage through auto-transformer
RVAT

Reduced Voltage trough soft starter
RVSS (SoftStart)
E&S - Tony Narusevicius - 20-09-2005 - English 1
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Direct stator starting on full voltage (FVNR)
Locked rotor current on starting is around 4 to 7 In depending on motor
characteristics
starting time of 1 to 10 seconds depending on the moment of total
inertia (motor + machine), motor torque and load torque

the network must be able to withstand the starting current without
disturbing other loads
the machine being driven must be able to withstand the mechanical
impact due to the motor torque

This mode is very popular (simple, robust, not expensive)
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Protection Load Motor
E&S - Tony Narusevicius - 20-09-2005 - English 1
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Reduced voltage by reactance
This starting mode reduces current inrush on the network in the simplest
manner. Since the motor starting torque is low, the machines being driven
must have a relatively low torque during star up: compressors; centrifugal
pumps; converter sets....

T/Tn
T L1shunted
T with L1
Tr
N
Nn
resistant torque
N1
1
2
Tmax
I
Id/In
N
Nn N1
2
4
In
If(Tr)
I L1shunted
I with L1
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L1 Protection
Load Motor
E&S - Tony Narusevicius - 20-09-2005 - English 1
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Reduced voltage by auto-transformer
This system is recommended for high power motors. It has the advantage
of not dissipating energy.
It can be used to obtain, for the same decrease in current, less reduction in
torque than with the reactor starter.
N1
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Ct3
Ct2
Ct1
Protection
T/Tn
Tr
N
Nn
resistant torque
N1
1
2
Tmax
I
Id/In
N
Nn N1
2
4
In
If(Tr)
Load Motor
E&S - Tony Narusevicius - 20-09-2005 - English 1
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Auto Transformer starting Sequence
Second stage:
the motor is running in series with part of the
autotransformer winding.

The motor is always supplied during the
second stage, when CT1 is open.


First stage:

CT1 must be closed before CT2.

CT1 and CT2 are closed

CT3 is open
CT1
CT2
CT3
M
Second stage:

CT1 is opened

CT2 remains closed

CT3 remains open

CT1
CT2
CT3
M
CT1 is opened
CT2 are closed
CT2 and CT3 are closed
Third stage:
the motor runs at full voltage.
First stage :
the motor is starting with reduced voltage.

Third stage:

CT3 is closed

CT2 remains closed

CT1 remains open

CT1
CT2
CT3
M
E&S - Tony Narusevicius - 20-09-2005 - English 1
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Reduced voltage by Soft Starter
The soft starter is an solid state device which controls the starting period
of the motor
depending on the application several settings are possible.
When the motor is running a contactor shunts the electronic starting
module.
Advantages
Reduction of starting current
Reduction of starting torque and mechanical shock ( the torque may
be adjusted to the resistant torque)
smooth acceleration and deceleration of the motor
It is a solution when auto-transformer motor starter is not possible.
But it is not a variable speed starter
Only the price limits the use of the Soft Starter
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Soft starter Protection
Load Motor
E&S - Tony Narusevicius - 20-09-2005 - English 2
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Soft starter setting: different possibilities
current limitation setting
torque control setting
mix of both
........

deceleration possibilities
E&S - Tony Narusevicius - 20-09-2005 - English 2
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Soft starter setting: current limitation
T/Tn
Tr
N
Nn
resistant torque
N1
1
2
Tmax
fix frequency
T=function
U
Un ( )
2
I and Torque
Is/In
I
l

T
sn

T
limited

limited T= Tn * (In / Il)2
N
Nn N1
2
4
In
If(Tr)
Limit of the starting current
The voltage is increased until the starting current reaches the limit, then voltage is maintained
at this current, and then the voltage is increased again up to the service voltage
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Soft starter Protection
Load Motor
E&S - Tony Narusevicius - 20-09-2005 - English 2
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Soft starter setting: torque control
The voltage is set to have a motor torque just above the resistant torque.
If the resistant torque is constant the starting voltage may be close the full voltage; the inrush current maybe
close the direct on line inrush current
T1 = k. I1
F
1

N and T C
t
t1
Tn
Nn
resistant torque
I and T
t
t1
I1
In
x In
Tn
T1
U1
I starter
Un
resistant torque
torque control
U starter=> F
speed ramp
fonction of
torque ramp
Load Motor
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Soft starter Protection
E&S - Tony Narusevicius - 20-09-2005 - English 2
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Soft starter: normal setting
The initial torque setting applies sufficient voltage to the motor to cause the motor shaft to
begin to turn.
This voltage is gradually increased overtime (as per the ramp time setting) until either:
the motor accelerates to full speed
the ramp time expires
a current limit is reached.
If the motor has not reached the full speed at the end of the ramp setting, the current limit
setting will proportionally control the maximum output torque
The current remains limited for as long it takes the motor to accelerate to full speed.

When the motor reaches full speed and the current drops to running level, the by pass
contactor shunts the soft starter module.The motor is now running at the full voltage.

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Soft starter Protection
Load Motor
E&S - Tony Narusevicius - 20-09-2005 - English 2
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Soft starter setting: deceleration
The starter may be used to control the deceleration by slowly reducing the voltage to the motor
upon initiating a stop command


the most common application for the decel feature is pumping application, in which a
controlled stop prevents water hammer and mechanical damage to the system.
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Soft starter Protection
Load Motor
E&S - Tony Narusevicius - 20-09-2005 - English 2
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Starting mode selection table
application Starting
mode
Controlled
by
Advantages
disadvantages
Permanent or
quasi
permanent
process<1/day
Machines requiring
high start torque
1 Circuit
breaker or
1 contactor
Frequent
starts>1/day
Motor with low
current inrush or
low power
Direct On Line /
Full voltage 1 contactor
Simplicity,
less investment
On starting:
High torque
High current inrush
High mechanical stress
Pumps fans,
compressors,
frequent starts
Machines starting
with low torque Stator by
reactance
Reduction of current in rush
on starting
Poor power factor
Optimisation
of starting
characteristics
When starting
current must be
reduced, but the
necessary starting
torque maintained
Stator by
autotransformer
or soft starter
3 contactors
2 contactors
Optimisation of torque and
current inrush on starting
expensive
Optimisation
of high torque
starting
characteristics
The most difficult
starts
rotor generally
3 contactors
Small current inrush and
high starting torque
E&S - Tony Narusevicius - 20-09-2005 - English 2
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Network requirement
Starting mode selection table
- accepts the current oscillation
during an open transition?
-accepts the starting reactive
consumption power?
Investment Increase

- deceleration control ?
- constant torque with high starting
torque as crushers, grinders, mixers ......
- the drive between motor and load
is able to withstand the mechanical
stress of a direct on line start
- accepts full starting current?
- accepts starting voltage drop?
yes
yes
yes
yes
no
no
no
no no
no
yes
yes
no
no
- accepts the harmonics during
the starting period
VSD
specific
no
FVNR RVAT RVSS
yes
yes
yes
E&S - Tony Narusevicius - 20-09-2005 - English 2
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main protection
overload overcurrent, thermal image, and thermal sensors
short circuits To protect the motor and the network
fuses and instantaneous over-current relay
thermal protection bearing overload temperature
simulated by relay
thermocople
RTD
Incomplete phase, phase
reversal and unbalance
faults give rise to:
increased current in the stator
insulation fault in the
winding
earth leakage protection
(differential protection)
stator/ frame vital to comply with the worker protection
protection windings and magnetic circuit
zero sequence current relay
under and over voltage under-voltage: common protection, prevents the motor on
working on overload
over-voltage: fluctuations on the network
incomplete starting or
frequent starts
prevents long motor starting and over temperature
speed or current
locked rotor protection of the motor against thermal damage
under power or
undercurrent
mainly for pumps
other protection specified by motor manufacturers
E&S - Tony Narusevicius - 20-09-2005 - English 2
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Rating Current of the contactor
The power of a motor is the mechanical power.
To determine the rating of the contactor we have to calculate the
full load current of the motor.
The electrical power of the motor will be the mechanical one
divided by the efficiency.
Is= Pm/(Us x V3 cosj *h)
where
Pm: power of the motor
Us service voltage
cosj power factor
h efficiency of the motor

Ir contactor > Is * k (k derating factor)
if the altitude <1000m k=1

Altitude (ft) Voltage Current
3300 (1000 m) and below 1.00 1.00
5000 (1500 m) 0.95 0.99
10,000 (3000 m) 0.80 0.96
E&S - Tony Narusevicius - 20-09-2005 - English 2
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What do you think?
For an asynchronous motor,
true false
the highest starting torque is supplied by the Full Voltage Motor starter
the higher the voltage, the higher the starting torque
with a full voltage motor starter the network capability to accept the inrush current needs to be verified
the inrush current may generate a voltage drop at the terminals of the motor
the distance between the motor starter and the motor has no influence on motor starting
motor starting through an auto-transformer is always a cycle of three steps
it is possible to continuously operate an auto transformer motor starter on an intermediate step
the auto transformer motor starter may be used for every application
the auto transformer is generally designed in accordance with the motor use for each project
different starting configurations are available in the soft starters
Soft starters use an electronic device to reduce the voltage
Soft starters maybe used to adapt the running speed
Soft starter maybe used to control the deceleration
soft starter needs 2 contactors
with a soft starter it is possible to adjust the starting torque to the resistant torque
E&S - Tony Narusevicius - 20-09-2005 - English 3
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Do you agree?
For an asynchronous motor,
true false
the highest starting torque is supplied by the Full Voltage Motor starter
the higher the voltage, the higher the starting torque
with a full voltage motor starter the network capability to accept the inrush current needs to be verified
the inrush current may generate a voltage drop at the terminals of the motor
the distance between the motor starter and the motor has no influence on motor starting
motor starting through an auto-transformer is always a cycle of three steps
it is possible to continuously operate an auto transformer motor starter on an intermediate step
the auto transformer motor starter may be used for every application
the auto transformer is generally designed in accordance with the motor use for each project
different starting configurations are available in the soft starters
Soft starters use an electronic device to reduce the voltage
Soft starters maybe used to adapt the running speed
Soft starter maybe used to control the deceleration
soft starter needs 2 contactors
with a soft starter it is possible to adjust the starting torque to the resistant torque
for some application the soft starter may create inrush current similar to the full voltage motor starter