Reduced Voltage Motor Starting Basics

Distributor Sales Training

April 2013

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

Background

 Pre 1970’s Only Electro-Mechanical Reduced Voltage Starters were

available:
 Auto Transformer
 Part Winding
 Wye-Delta (Star-Delta)
 Primary Resistance
 Primary Inductance
 Wound Rotor

Carbon Disc

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Motor Characteristics

 Rotor resistance
End Bell
 Air gap
 Rotor bars and slots Wiring Stator
 disposition Cover Winding
 shape
Fan
Blades
Motor
Frame

Rotor

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

Why use Smart Motor Controllers?
Minimize operating cost, 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: Percentage of Full Speed

 Lengthens system life by reducing mechanical stress during starting– Reduces

DOWN Time
 Helps eliminate the need for maintenance people to repair the process
 No need to replace damaged parts
 Minimize production losses
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Why use Smart Motor Controllers?
Meet power company restrictions and lower peak charges

 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%
 SMC Solution: Percentage of Full Speed

 Current Limit starting minimizes the amount of inrush current, meeting power
company restrictions and lowering peak demand charges
 Process shut down and brown outs are minimized by reducing the amount of current
drawn during starting
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Motor Characteristics
Reduced Voltage  Reduced Torque
 A 50% reduction in the applied voltage results in a 75% reduction
in generated torque.

(.5)2 = .25 or 25% of Locked

Rotor Torque
180%

100%

0 100%
Percentage of Full Speed
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Motor Characteristics
Reduced Voltage  Reduced Current
 With the applied voltage reduced 50%, the starting current is lowered
proportionally. The resulting “up-to-speed” time is longer due to the
reduction in torque.
600%

Percentage
of Full Load
Current

100%

0 10 seconds 40 Seconds
Acceleration Time in Seconds
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Selecting a Starting Method

Considerations
 Starting torque requirement of the load
 No load
 fan or centrifugal pump
 Full load
 extruder or positive displacement pump

 Motor characteristics
 Power source limitations

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

Controlling the Voltage

The key to controlling the torque or current to a motor is

controlling the voltage applied to the motor
 Essentially two-methods for controlling voltage
 Electro-Mechanical Devices
 Utilize various mechanical means including contactors, timers, resistors and
transformers
 Some methods require special motors

 Solid State devices

 Use Solid State switching devices called SCR’s
 Simple products for all motors

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

Electro-Mechanical RV Starting Methods

 Electromechanical device operation involves a transition that can

cause a current and torque spike

600%

Percentage Transition
of Full Load
Current

100%

0 100%
Percentage of Full Speed
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Electro-Mechanical RV Starting Methods

Transition to Full Voltage

 Two methods
 open circuit (motor disconnected from the line during
transition)
 closed circuit (motor remains connected to the line
during transition)
 Both present an associated current surge when
transition occurs

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

Electro-Mechanical Starting Methods
Types of Electromechanical Reduced Voltage Starters

 Primary Resistance
 Wye Delta
 Autotransformer
 Part Winding

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Electro-Mechanical Starting Methods

Primary Resistance Starter

During the start cycle, the Primary Resistance starter inserts resistance
in series with the motor windings. The voltage drop across the resistors
results in reduced voltage being applied to the motor. At some point
later in the start cycle, the resistors are shunted.

Power
Motor

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Wye-Delta Starter (A-B Bulletin 540)
 Starting current : 200% of motor Disadvantages:
rated current  Non-standard squirrel cage motor (6 or
 33% of normal starting torque 12 leads)
 Open and closed circuit transition  Starting torque is at a relatively low,
are available “fixed” level
 No ability to compensate for varying
loads
Advantages:
 Relatively high installation cost - two
 Produces the greatest amount of
starting torque per ampere of motor pair of motor cables
current
 reduced motor heating 277 V
480 V
 Relatively inexpensive
 no voltage reducing
components (i.e. resistors or WYE DELTA
transformers) required
(277/480)2 = .33 or 33% (480/480)2= 1 or 100%

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Autotransformer Starter (A-B Bulletin 570)
 Three coil starting transformer with taps
at 50%, 65% and 80%
 Starting current : 300 - 480% of motor
rated current
 25 - 64% of normal starting torque
 Closed circuit transition is standard

Advantages:
 Delivers the highest starting torque per
line ampere
 Taps provide flexibility to obtain varying
levels of starting current and torque
 Autotransformer starters can be applied
to standard squirrel cage motors
Disadvantages:
 Typically more expensive than other
electromechanical methods of reduced
voltage starting
 Enclosure size necessary to package all
the required components is significantly
larger than in other methods
 Maintenance is more complex due to
additional components
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Part Winding Starter (A-B Bulletin 530)
 Starting current: 400% of motor rated
current
 45% of normal starting torque
 Full voltage is typically applied to the
motor within 2 seconds after start

Advantages:
 Transition is inherently closed circuit
 Relatively inexpensive
Disadvantages:
 no voltage reducing components (i.e.
resistors or transformers) required  Non-standard squirrel cage motor
 uses two half-sized contactors  Relatively high installation cost - two pair
of motor cables
 Fusing must be proportionately smaller

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Solid State Starter Evolution

 The solid-state starter is by far the most

Gate
flexible of all the reduced voltage starting
methods.
 This method utilizes Silicon Controlled SCR
Rectifiers (SCR’s) for switching power to the
connected motor.
 The SCR is triggered “on” by energizing the
gate.

1970’s 1986 2002

Dialog SMC 3 &
TI SCR’s SS RVS Bul. 730 Bul. 2050 Bul. 150 SMC-50
Plus Flex

1968 1984 1995 2012

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Solid State Starter Technology

 The SCR will allow current to flow in only one direction

 Once the AC voltage changes from positive to negative, the SCR will not
conduct again until the voltage is positive and the gate is triggered

Gate
V In V Out
SCR

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Solid State Starter Technology

 By controlling when an SCR is fired in the cycle, the output voltage can be
controlled.

 Also, by using SCR’s in an “opposed” (back to back) configuration, the full

sine wave of the AC power can be controlled.
Gate Signal
Gate

SCR

VIN VOUT

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Solid State Starter Technology

 Principles of Operation
 Fixed Frequency (50 or 60 Hz)
 Operational between 47 – 63 Hz
 Voltage Controlled through the use of SCR’s
 6 back-to-back SCR’s
 Microprocessor Logic Controls SCR’s firing
 Phasing back the SCR’s Reduces Voltage to Motor

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.Copyri

Compare Reduced Voltage Starting

Voltage
Adjustment Resulting
Starting Method Range Transition Type Torque

Primary Fixed % Current

Resistance Step/Steps Closed Squared
Auto XFMR 50/65/85% Closed 25/42/72%
Wye-Delta 33% Open or Closed 33%
Solid State 0-100% Step-Less 0-100%

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

Solid State Motor Starting Comparison
RV Solid State Starter
 Controls starting and stopping
 During reduced voltage starting, torque
is reduced
 Simple to adjust and setup
 Internally bypassed versions are
extremely efficient when running at full
speed
 Cost
 Below 15 HP – Similar to Drive
 Above 15 HP - Lower Cost
AC Frequency Drive
 Can vary the speed of motor at any time
during the process for any duration –
true Continuous Control
 Can deliver full torque at any speed
without sacrificing current
 Can be more complex to setup or install
 May require additional hardware (i.e.
AC Line Filters) to meet Harmonic
content specifications
 Cost
 Very competitive below 5 HP
 Cost Increase with HP
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
Advantages of Solid State Start Control

• Enhanced Control Options

– User Programmability
– Scalable to critical nature of application
– Local, Manual, Automatic Modes

• Inherent Diagnostics
– Current, Voltage, Power & Energy Monitoring
– Faults and Alarms

• Lowest Installed Cost with Network Integration

– Ease of Communication Linkage (i.e. multi protocol, AOP’s)
– Localized I/O and control
– Wire Reductions

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

Questions? Thank You…

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