T76 Practical Applications of Soft Starter Technology

Soft Starter Technology
Applying SMCs to maximize investments and energy efficiency
Rev 5058-CO900B
Copyright 2012 Rockwell Automation, Inc. All rights reserved.
RAOTM - Topic
Title:
Practical applications of Soft Starter technology for improved performance
and energy management
Description:
Increase your technical competency and understanding of the latest Soft
Starter technology, and find out how SMC's can be applied to maximize your
investment and energy efficiency. This session will include a brief overview
on technology, recent advancements, application examples and
considerations, use of the SMC Application Wizards, and an overview of the
Allen Bradley SMC portfolio.
Agenda
UnderstandSoft
SoftStarter
StarterTechnology
Technology
Understand
RecentAdvancements
Advancements
Recent
ApplicationExamples
Examplesand
andConsiderations
Considerations
Application
ApplicationWizards
Wizards
Application
AllenBradley
BradleySMC
SMCPortfolio
Portfolio
Allen
Copyright 2012 Rockwell Automation, Inc. All rights reserved.3
AC Motor Control Basics
Basic
Advanced
Reduced Voltage Starter Background

Pre 1980s RVS Types
Todays RVS
Auto Transformer
Solid State RVS
Part Winding
Voltage controlled through use of SCRs
Wye-Delta (Star-Delta)
Primary Resistance
SCR triggered ON by energizing the Gate
Primary Inductance
Microprocessor monitors and controls when
Wound Rotor
(Silicon Controlled Rectifiers)
6 Back to Back SCRs
SCRs fire
Gate
SCR
Electromechanical Solid State

Solid State Starting Basics
SCR Control
A. Using SCRs in an opposed (back to back) configuration, the full sine wave of the
B.
AC power can be controlled.

By controlling when an SCR is fired in the cycle, the output voltage can be
controlled. The result is sometimes called a Notch.
Gate Signal
Gate
SCR
VOUT
VIN
B
Soft Motor Starting Basics
Typical Motor Starting Curve

Starting Torque
(Lock rotor torque)
Full Voltage
Starting Characteristics
Starting Current
~6xFLA
Break-down
torque
Pull-up torque
180%
Full load
torque
100%
Speed -%RPM
100%
High starting torque can cause damage to the mechanical system.

High current can cause problems in the electrical system

Physics of Reduced Voltage and Motor Torque
If you reduce voltage by 50%, the result is a 75% reduction in motor torque.
(.5)2 = .25 or 25% of Locked
Rotor Torque
180%
Percentage
of Full Rated
Torque
100%
Full Voltage Torque
Reduced Voltage Torque
Percentage of Full Speed
100%
100
%
72%
300%
%FLA
510%
100% Voltage
(amps)
600%
85% Voltage
(ftlb)
Torque
Example
Full Load
50% Voltage
25%
0
Current
Torque
Speed -RPM
100
%
Torque required
by the load
Reasons for Soft Motor Starting

Minimize mechanical damage of system components and product
Belts, Gears, Drive Shafts and Keyways
Reduced Product Spillage
Water Hammer and Mechanical Vibration
Better Energy Management

Limit in-rush current
Optimize the size of transformers/generators/switch gear
Meet Power Company Requirements / Rebate programs
Manage Control under Power Distribution Limitations
Energy Cost Reduction (Peak Demand Charges)
Agenda
UnderstandSoft
SoftStarter
StarterTechnology
Technology
Understand
RecentAdvancements
Advancements
Recent
ApplicationExamples
Examplesand
andConsiderations
Considerations
Application
ApplicationWizards
Wizards
Application
AllenBradley
BradleySMC
SMCPortfolio
Portfolio
Allen
Electromechanical vs. Solid State

Solid State delivers greater flexibility
Allow for the starting current/torque to be optimized versus standard reduced

voltage starter types
Example Star-Delta reduced voltage starter is fixed at 300% current/33% Torque
Solid State insures minimal amount of energy to accelerate motor even if the load only
requires 25% torque.
SS eliminates transitions due to electromechanical limitations
Open or Closed transitions

Open disconnects motor from line voltage, Closed maintains connection to line
Both cause current surges during start
Starting Voltage Adjustment
Transition
Resulting Torque
Method
Range
Primary
Fixed Step/Steps
Closed
%Current Sqd
Resistance
Auto Xfmr
50/65/85%
Closed
25/42/72%
Wye-Delta
33%
Open or Closed
33%
Solid State
0 - 100%
Stepless
0 - 100%
Advantages of Solid State Control

Enhanced Control Options
Advanced Start/Stop control

User Programmability and settings
Scalable setting for the critical nature of application
Local, Manual, Automatic Modes
Inherent Diagnostics
Current, Voltage, Power and Energy Monitoring/protection

Faults and Alarms (some based on real time clock)
Controller Event logs and Snapshot (what happened right before a fault)
Lowest Installed Cost with Network Integration
Ease of Communication Linkage (i.e. multi protocol, AOPs)

Localized I/O and Control
Wire Reductions
2 Phase Vs. 3 Phase Control

Comparison
2 Phase Control Advantages
Lower initial cost
Smaller overall total size
2 Phase Control Disadvantages
Higher Peak Currents/Imbalance
2 Phase
3 Phase
Regardless of control methodology
Increased Heating
Increased Vibration during Starting
3 Phase control provides superior performance on every start!

Advances in Starting/Stopping Modes

SMC-50 Patented Linear Acceleration Starting Mode
Simplest Starting Mode
Lowest starting current profile per start
Regardless of loading condition
Ideal for any application

Provides control over both torque and speed
Unmatched motor starting performance
Selected start time closer to actual than any other stating method*
Starting Performance Comparison

Linear Accel vs. Traditional Soft Start: Centrifugal Pump Load
High Torque Pulse/Surge and
water hammer
iv l
c/Dc tota
e
2 S 3 Se
=
2 Sec/Div = ~10 Sec

Higher Peak Current
Current more stable and

less disruptive to power
system
Time
Parameter Settings: = Start Time: 10 second
Starting Performance Comparison

Linear Accel vs. Traditional Soft Start: High Inertia Load
Torque Pulse/Mechanical Wear and Tear
2 Sec/Div = ~10 Sec

2 Sec/Div = ~6 Sec
Higher Peak Current
Current more stable and

less disruptive to power
system
Time
Parameter Settings: =Start Time: 10 second
SMC Soft Starters

Power and Energy Management
Green Initiatives
Allow users to qualify for Energy focused based rebates and discount programs
Help reduce energy consumption and waste
Facility wide information enablement via Intelligent Motor Control
Sustainability and Sustainable Production
Deliver a return on investment with scalable products
Reduced downtime and maintenance costs
Energy Savings
Reduce the total amount of energy consumed
(Energy Saver in SMC-50)
Reduce the total cost of energy
Soft Starters and Energy Management

Reduction of the peak inrush of a motor (i.e. peak current)
Reduces the peak demand charges
Charges are determined by utility based on the peak energy usage
Advantages of Controlled Demand
Allows for the facility to optimize/maximize distribution

Smaller gensets or transformers (incl. feeders wires etc.)
Allows the power company optimize/maximize distribution

Possible reduced installation cost based on system demands
Scalable Performance
SMC Flex and SMC-50 Provide advanced Power and Energy Monitoring
Measurement it = manage it
Visibility = helps provide business case support for future process and product improvements
Agenda
UnderstandSoft
SoftStarter
StarterTechnology
Technology
Understand
RecentAdvancements
Advancements
Recent
ApplicationExamples
Examplesand
andConsiderations
Considerations
Application
ApplicationWizards
Wizards
Application
AllenBradley
BradleySMC
SMCPortfolio
Portfolio
Allen
Motor Starting Comparison

SMC Soft Start
Full Voltage (DOL)
Simplest Starting Solution
VFD/Drive
Simple Starting and Stopping
Full torque applied to motor

Mechanical wear
~6x inrush current
Peak demand charges
Limited Control at various speeds
Complete Continuous Control at any

Speed
Reduced torque and current during

starting
Full torque at any speed without

sacrificing current
Limited Functionality
Unless used with
advanced Overload
Simple to adjust and setup
Reduced installation costs

Smaller footprint
No need for harmonic/EMC
mitigation
Highly efficient motor and application

performance
Finite Mechanical Life

Contacts will wear out
Highly efficient when running at full speed

Energy Saver Performance for light loads
Up to 15 different starting modes
More complex setup and install

Larger footprint
Impact on Power Quality
Application Considerations
Motors types
Lead Lengths
Wire Type
Ambient Conditions
Selecting a Starting Method
When do I specify a drive versus a soft starter?

Speed Control is required
Consistent Acceleration and Deceleration (New SMC-50 exception)
High starting torque required
Continuous Feedback (critical position control)
Custom starting and stopping maneuvers
Faster stopping with Dynamic braking options
Drive can hold rotor at zero speed
Undersized or closely matched motor or power source
Why Use SMC Controllers?

Minimize Operating Costs, Reduce Down time
Problem:
Belts, gears and machinery can be damaged by across-the-line starting

Breakdown Torque
180%
High torque can cause

physical damage to the
mechanical system.
100%
Percentage
of Full Load
Torque
0
100%
SMC:
Lengthens system life by reducing mechanical stress during starting Reduces DOWN Time
Helps reduce/eliminate PMO on equipment
No need to replace damaged parts
Minimal production loss
Why Use SMC Controllers?

Minimize Operating Costs, Reduce Down time
Problem:
Power company restrictions on incoming line current, or you pay the penalty
Weak power lines cannot handle high inrush currents, causing brown outs or excessive line
disturbances, which in turn cause other processes to shut down
600%
Percentage
of Full Load
Current
100%
0
100%
How to apply SMC Controllers

Determine the main reason for using reduced voltage?
Mechanical?
Power Limitations?
Simplicity?
Select the best solid state control mode
Soft Start
Soft Stop
Current Limit
Soft Start/CL with Kick Start
Pump Control
Torque Control
Linear Acceleration/Deceleration
Special Modes
Dual Ramp
Full Voltage
Slow Speed
Custom Starting Profiles
Smart Motor Braking
Combination of profiles
Standard Starting Methods

Current Limit
Primarily used to limit line disturbances
Constant or very lightly loaded motor
Good on high inertia applications
Bandmills, Fans, Centrifuge, Ball Mill, Washers
Soft Start
Primarily used to limit mechanical stress

Constant or exponentially increasing loads
Compressors, Pumps, Conveyors
Soft Start/Current Limit with Kick Start
Kick Start is needed to overcome static condition

Example: Cold system components, loaded conveyor
Full Voltage
Not a common Starting mode.

NOTE: Full voltage required to accelerate the motor may be a sign of
other problems (i.e. Initial Torque of > 90%)
Used as a Solid State Contactor for High cycle rates

Standard Starting Methods

Pump Control
Legacy version of torque control optimized for centrifugal loads
Simple to apply but some considerations
Exponentially increasing load such as Compressors, Pumps, Conveyors
Torque Control
Similar to Pump Control performance but applicable for all load types
More difficult to apply but yields higher level of performance
Linear Acceleration/Deceleration
Simplest starting, lowest current , most consistent starting time per start regardless of load
Pump Control in SMC-Flex & SMC-50

Designed for Centrifugal Pumps
Applications lightly loaded at zero speed

Reduces surges (water hammer) caused by uncontrolled acceleration and deceleration
Can eliminate the need for specialized flow control valves
Ease of pump configuration
Provides control without the use of sensors or feedback devices
Pump Control Compared to Linear Acceleration
No advantage, other than legacy migration
Pump Control Compared to Torque Control
Easier to set up and optimized for centrifugal pumps
Not intended for Positive Displacement Pumps

Full Load required at zero speed
Variable Speed typically required to control flow
SMC-Flex & 50 Pump Control

DOL
Start
Excess
energy/power
Torque
Full
Load
Soft Start
Pump Start
Pump System
Speed
Full Speed
SMB Smart Motor Braking

SMC Flex and SMC-50
The SMB Smart Motor Braking is designed to stop a motor quickly
No additional hardware or feedback devices are required

Automatic zero speed shut off is integrated into the controller
SMB Smart Motor Braking

SMC Flex and SMC-50 Considerations
How fast do you want to brake?
Rule of thumb: It will take you at least 1.5 times as long to brake a
motor as it will to start (3 to 4 times is more typical)
How much power can you use for braking?
Rule of thumb: Anything more than about 300% can play havoc with
power systems and cause nuisance tripping or worse.
Can the power system handle the demands of braking current for the
entire duration of the stop?
How consistent does the brake time need to be?
A good power supply is critical to consistent braking
Good line Voltage regulation is the key to successful braking!
SMB Common Concerns/Questions

Braking is hard on the motor?
True, Braking regardless of the method, is hard on the motor windings
Noise is common during braking?
True, moans and groans of all kinds can be heard in a motor during braking
Braking produces increased Harmonic distortion?
True, the SMC produces some harmonic distortion during starting and stopping, however the
levels are insignificant (typically < 10% of the fundamental)
SMB is a good alternative for Critical braking?
False, SMB is not intended to be used for E-Stop scenarios. To many variables are involved
which can alter the performance of this feature
The SMB option damages motors?
False, Braking is hard, but we can not create more energy then what the motor demands.
Motor damage is typically caused by incorrect settings or normal wear and tear
Smart Motor Braking is an exact science?
False, Most applications are dialed in via trial and error

SMC
Special Application Considerations
Multi-Motor Applications
Mechanically Coupled (Transmission, direct gear drive, Conveyors)
Single SMC for multiple motors

Separate Overload protection required
Not Mechanically Coupled (No physical connection)
Separate SMCs per motor

One SMC Not Recommended
Reduced Performance and adjustability

Too much variability in motor characteristics
Cost advantage with Adj.Freq. Drive, but less with SMC
SMC
Power Source Sizing Guidelines
Ideally, the source would be sized for a full voltage start. (Somewhat impractical today)
When sizing for use with a generator it is critical that the generator is able to stay in proper
regulation under starting or braking loads.
Rule of thumb: Avoid sizing the supply for anything less the 300% of the motors FLA.
SCR Fusing for SCR Protection (Very Fast Acting Semiconductor type fuse)
Limited usefulness with SMC-Flex and SMC-3, due to bypass operation
Use is not suggested in High Inertia, Braking, or Pump stop applications (Applications with
Start times > 30 seconds) due to potential for nuisance tripping
Can be used to achieve Type 2 Coordination in some cases
See SMC Wizard Short Circuit Protection (SCPD) Wizard for further guidance
SMC
Power Factor Correction Capacitors
Line side only - locating load side can damage the SCR
Ideally PFCC are brought in with up-to-speed contact
Dynamic Correction can be responsible for nuisance line faults
Transient/Cyclic Spikes of Current Due to Load Variation
Examples: Rock Crushers, Wood Chippers, Band Saws, etc.

With the SMC-Flex & SMC-3, Spikes 120% of controller max frame rating causes the bypass
to drop in and outNOTE: If this is happening a lot, the SMC is likely under sized for the application
Insure the FLA adjustment/programming is correct for the motor operation
SMC-3 and Soft Stop
For best operation try to size SMC-3 mid range per Selection Guide/Catalog
Sizing the starter for the application

Selection guides are correct for 90% of applications (Pumps, Fans, Compressors)
Simply choose based on voltage, horsepower, current and insure that the motor FLA
fits the SMCs operating range
10% of applications may require a closer look

Application Analysis: Load with potential high starting inertia or minimal load
Flywheel, chippers, grinders, braking, retrofits, running vs. starting req. etc.
Thermal Analysis may be required to determine proper size for the following:
Extended starting or stopping times (>30 sec)

Aggressive Duty Cycle (> 10 times/hr)
Operation in elevated (above 50C) ambient temperatures
LRA > 600% (i.e. High efficiency motors, NEMA Design A)
Solution to Assist: SMC Estimation Wizard

Agenda
UnderstandSoft
SoftStarter
StarterTechnology
Technology
Understand
RecentAdvancements
Advancements
Recent
ApplicationExamples
Examplesand
andConsiderations
Considerations
Application
ApplicationWizards
Wizards
Application
AllenBradley
BradleySMC
SMCPortfolio
Portfolio
Allen
SMC Application Wizards

Why use the Wizards (eTools)?
To provide a better Estimation to the applicability of a SMC-3, SMC Flex and SMC50 product to a given set of motor & load operating requirements.
SMC Application eTools

Thermal Wizard
Used for simple/quick analysis of SMC

capabilities from a thermal perspective
Short Circuit Protection Device
Used to guide selection of branch

circuit protection components
i.e. fuse or circuit breaker size
bypass and isolation sizing
Application Wizard
Used for advanced modeling of the

complete system including SMC
thermal capabilities and motor/load
starting characteristics
Wizards Available from:

ProposalWorks Tools pull-down or from:
http://ab.rockwellautomation.com/Motor-Control/Soft-Starters/SMC-Flex#/tab6
SMC Application eTools

SMC Applications built for mobile
phones and tablets
Cross platform support with all

major mobile operating systems
iOS, Blackberry, and Android
HTML 5 based applications
Allows for ease of use and

updating
Can run like any standalone
mobile application
Almost fully offline capable
Do an App Search for Rockwell Automation

Agenda
UnderstandSoft
SoftStarter
StarterTechnology
Technology
Understand
RecentAdvancements
Advancements
Recent
ApplicationExamples
Examplesand
andConsiderations
Considerations
Application
ApplicationWizards
Wizards
Application
AllenBradley
BradleySMC
SMCPortfolio
Portfolio
Allen
Solid State Power Control Portfolio
Performance / Functionality
SMC-50
SMC Flex
SMC Dialog
SMC-3
SSC
5
25
100
200
500
Ampere Rating (Line and Delta)
800
1000
1600
*Dialog supports line configuration only

Allen-Bradley
SMC Contemporary Offering
SMC-3
Hybrid Power Structure
SMC Flex
SMC-50
Solid State Power Structure
SMC Family
Choosing a Power Platform
True Solid State
Hybrid Solid State
AC53-B
Smaller
Total Footprint
Less
External Wiring
Optimized Thermal
Management
Easy Product
Selection
Lower Total
Installed Cost
Hybrid Solid State (Integral Bypass)

2 Thyristors per phase (6 total)
Thermal Mass
Small Stirring Fans
Integral Shorting or Bypass Contactor
True Solid State
2 Thyristors per phase (6 total)
Larger finned heat sinks & fans
Optional external bypass contactors
Ability to replace contactor

Ability to size contactor AC1 or AC3
AC53-A
Ideal for Harsh

Environmental
Conditions
Higher SCCR
ratings
Phase
Rebalance/Energy
Saver Capability
Higher
operations/hour
Scalable Thermal
Ratings
SMC Family
Choosing a Power Platform
Internal Bypass (SMC-3, SMC Flex)
Solid State (SMC-50, SMC Dialog, SMC Plus)
Ideal for small spaces
Ideal for critical performance in

tough environmental conditions
Smallest total footprint
Easy selection and application
Allows for Specialized Control
Lowest total installed cost
External Bypass offers

operational flexibility and
redundancy

SMC Family
Choosing the control for your application
Which control modes are required?
SMC-50, Flex & SMC-3
SMC-50, SMC-Flex
Soft Start
Soft Stop
Current Limit
Soft with Kick Start
Pump Control
Slow Speed
Dual Ramp
Full Voltage Starting
Smart Motor Braking
Linear Accel/Decel (SMC-50 Only)
Torque Control (SMC-50 Only)
The SMC Flex / 50 also offer power metering features as well as communication options
enhancing configuration, control and data collection capabilities!
SMC-3 Overview
Compact Series
Hybrid design (internal bypass contacts)

Simplified DIP and Rotary Set-up
Din Rail Mountable through 85 amps
4 Starting/Stopping Modes
Soft-start, Soft-stop, Current Limit, Kick Start
Basic Diagnostics
Compact design provides 3 phase control, increased intelligence, and unmatched
performance. Motor and system diagnostics and an electronics overload with adjustable
trip class help reduce downtime and protect assets.

SMC-3 Overview
Line Ratings
Frame 1 (3 A, 9 A,16 A, 19 A, 25 A, 30 A, 37 A)
Frame 2 (43 A, 60 A, 85 A)
Frame 3 (108 A, 135 A)
Frame 4 (201 A, 251 A)
Frame 5 (317 A, 361 A, 480 A)
Delta Ratings
3 831 amps
Two line voltage ratings
200480V or 200600V @ 50/60 Hertz
Two control voltage
24V AC/DC or 100240V AC
050C Operating temperature
SMC-3 can be applied to both line and delta connected applications!

SMC Flex - Overview

Modular Class
Hybrid design (internal bypass contacts)

Built-In LCD and Keypad
9 Start/Stopping Modes
3 slow-speed modes
Smart Motor Braking
Enhanced Diagnostics and Protection functions

Modular design features 3 phase control, advanced intelligence, performance
and diagnostics, communications flexibility, modular control module/power
modules/fan assembly for a cost effective package.

SMC Flex - Overview

Specifications
Line Ratings
5.1250 Amps
Delta Ratings
81600 Amps
Three Voltage Ratings
200 - 480V @ 50/60 Hz
200 - 600V @ 50/60 Hz
230 690V @ 50/60 Hz
Control Voltage Ratings
100-240 VAC or 24V AC/DC
0 - 50 C Operating Temperature
Starting Modes
Soft-Start
With selectable Kick Start
Soft-Stop
Current Limit Start
With selectable Kick Start
Full Voltage
Preset Slow Speed
Linear Speed Acceleration
Feedback Device Required
Dual Ramp
Pump Control (optional)
SMC-50 Product Overview

Scalable Series

NO Integral bypass like SMC-3 or SMC-Flex
Built-In HIM Cradle and PC port
15 Start/Stopping Modes
3 slow-speed modes
Smart Motor Braking
Advanced Diagnostics and Protection functions
Full power and energy management, Real Time Clock, Event Log
Designed for customer flexibility 3 phase control and scalable options help
maximize the total motor control investment. Advanced monitoring and protection,
superior communication capabilities and energy saver modes help increase
operating efficiencies and reduce downtime.

SMC-50 Product Overview

Benefits of a Fully Solid State Power Structure
(no integral bypass)
Improved performance in high vibration applications

Performance not impacted by environmental debris
Longer life (no mechanical life limits)
Scalable thermal ratings
Higher SCCR ratings
100 Ka Fuses
65 Ka Breaker
Thank You!
Find More Information on SMC Products
Visit us @ WWW.AB.com
Follow ROKAutomation on Facebook & Twitter.

Connect with us on LinkedIn.
www.rockwellautomation.com
Rev 5058-CO900B
Back-Up Slides
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Connect with us on LinkedIn.
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Rev 5058-CO900B
SMC-50 Modes of Operation

Starting Modes
Soft Start
Current Limit w/ Kick Start
Pump Control
EW!
N
Enhanced Slow Speed: 1% to 15%
!
NEW
Patented Sensor-less Linear Acceleration*
Consistent ramp up time (no tachometer
required)
Optimizes energy consumption
Torque Control NEW!

Full Voltage
Dual Ramp w/ Kick Start
Stopping / Specialty Modes
Coast
Soft Stop
Smart Motor Braking (SMB)
Linear Deceleration NEW!
External Braking Control NEW!
Pump Control
Motor Winding Heater NEW!
Energy Saver
Phases back voltage sensing lighter loads
Emergency Run
*SMC Flex provides Linear Acceleration Start, however it requires a tachometer for speed feedback

Linear Speed
Patented Sensor-less Linear Acceleration Starting Mode
Accomplished via Advanced Motor Speed Estimation Algorithm
No external feedback required - reduces cost and potential for failure

Provides exacting motor acceleration control under varying load conditions
Simplest to Setup
2 Parameters Required to configure: Ramp Time and Initial Torque (used as reference)
Reduces/eliminates the need for the Dual Ramp mode
Always uses the minimum amount of energy needed to accelerate the motor in the time requested
(regardless of the loading condition)

Torque Control
Torque Control can be used to control the maximum torque developed by the motor
independent of motor speed
Provides a torque ramp from an initial starting torque level to a maximum torque level
Mode also provides simple starting performance (Kick start available as an option)
Controlling torque does not allow control over speed of acceleration like Linear Accel.
Torque Control algorithms are useful for basic applications (pumps, compressors)
Basic Setup Parameters:
Ramp Time, Starting Torque, Max Torque(M), Rated Torque(M) and Rated Speed Settings(M)
(M) = motor rated value


Comparison Example
Linear Accel vs. Torque (Pump) Start: Pump Load
2 Sec/Div
= 10 Sec total
2 Sec/Div
= 5 Sec total
Higher Peak Current
Time
NOTEs:
- Actual Start time difference of Linear versus torque mode
- Smoother torque curve for Linear versus torque mode
- Lower peak current with Linear Acceleration mode
Parameter Settings: =Start Time: 10 second

Motor load = approx 65% of FLA
SMCs Differentiated by Innovation

Broadest offering of Features/Performance/Functionality in a Soft Start
Advanced Starting/Stopping Performance (Linear Mode)
True 3 Phase Control
Solid State or Hybrid Performance and Reliability
Simple to Advanced Fault, Power, and Energy Monitoring
High Fault SCCR ratings with Fuses and Standard Breakers

Special Modes
Slow Speed, Motor Winding Heater, Energy Saver, Phase Rebalance, DeviceLogix
Standard features cover multiple dedicated devices
Improved Troubleshooting, Diagnostics Accuracy and time stamping
Power Monitors, Scopes, ETMs, Motor Winding Heaters, DC Brake etc.
Standard Open and Enclosed offerings

T76 Practical Applications of Soft Starter Technology

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T76 Practical Applications of Soft Starter Technology

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Soft Starter Technology

Applying SMCs to maximize investments and energy efficiency

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Copyright 2012 Rockwell Automation, Inc. All rights reserved.3

AC Motor Control Basics

Reduced Voltage Starter Background

Solid State RVS

Voltage controlled through use of SCRs

SCR triggered ON by energizing the Gate

Microprocessor monitors and controls when

(Silicon Controlled Rectifiers)

6 Back to Back SCRs

Electromechanical Solid State

Solid State Starting Basics

AC power can be controlled.

Soft Motor Starting Basics

Typical Motor Starting Curve

High starting torque can cause damage to the mechanical system.

Soft Motor Starting Basics

Full Voltage Torque

Reduced Voltage Torque

Percentage of Full Speed

Soft Motor Starting Basics

Copyright 2012 Rockwell Automation, Inc. All rights reserved.9

Reasons for Soft Motor Starting

Better Energy Management

Copyright 2012 Rockwell Automation, Inc. All rights reserved.10

Copyright 2012 Rockwell Automation, Inc. All rights reserved.11

Electromechanical vs. Solid State

Allow for the starting current/torque to be optimized versus standard reduced

SS eliminates transitions due to electromechanical limitations

Open or Closed transitions

Copyright 2012 Rockwell Automation, Inc. All rights reserved.12

Advantages of Solid State Control

Advanced Start/Stop control

Current, Voltage, Power and Energy Monitoring/protection

Lowest Installed Cost with Network Integration

Ease of Communication Linkage (i.e. multi protocol, AOPs)

2 Phase Vs. 3 Phase Control

Regardless of control methodology

3 Phase control provides superior performance on every start!

Advances in Starting/Stopping Modes

Ideal for any application

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Starting Performance Comparison

2 Sec/Div = ~10 Sec

Current more stable and

Starting Performance Comparison

2 Sec/Div = ~10 Sec

Current more stable and

SMC Soft Starters

Reduced downtime and maintenance costs

(Energy Saver in SMC-50)

Reduce the total cost of energy

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Soft Starters and Energy Management

Reduces the peak demand charges

Charges are determined by utility based on the peak energy usage

Advantages of Controlled Demand

Allows for the facility to optimize/maximize distribution

Allows the power company optimize/maximize distribution

Copyright 2012 Rockwell Automation, Inc. All rights reserved.

Copyright 2012 Rockwell Automation, Inc. All rights reserved.20