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There are four major motor control topics or categories to consider. The four categories include:
1) Starting the Motor Disconnecting Means Across the Line Starting Reduced VoltageStarting 2) Motor Protection Overcurrent Protection Overload Protection Other Protection(voltage, phase, etc)\Environment 3) Stopping the Motor Coasting Electrical Braking Mechanical Braking 4) Motor Operational Control Speed Control Reversing Jogging Sequence Control
MOTOR STARTING
All motors must have a control device to start and stop the motor called a motor controller.
Motor Controller
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A motor controller is the actual device that energizes and de-energizes the circuit to the motor so that itcan start and stop.Motor controllers may include some or all of the following motor control functions: starting, stopping, overcurrent protection, overload protection, reversing, speed changing, jogging,plugging, sequence control, and pilot light indication. Controllers range from simple to complex and can provide control for one motor, group of motors, or auxiliary equipment such as brakes, clutches,solenoids, heaters or other signals.
Motor Starter
The starting mechanism that energizes the circuit to an induction motor is called thestarter and must supply the motor with sufficient current to provide adequate starting torque under worst case line voltage and load conditions when the motor is energized.
If the driven load or the power distribution system cannot accept a full voltage start, some type of reduced voltage or "soft" starting scheme must be used. Typical reduced voltage starter types include: 1. Solid State (Electronic) Starters 2. Primary Resistance Starters 3. Autotransformer Starters 4. Part Winding Starters 5. Wye-Delta Starters Reduced voltage starters can only be used where low starting torque is acceptable or a means exists to remove the load from the motor or application before it is stopped.
Overcurrent Protection
Overcurrent protection interrupts the electrical circuit to the motor upon excessive current demand on the supply system from either short circuits or ground faults. Overcurrent protection is required to protect personnel, the motor branch circuit conductors, control equipment, and motor from these high currents. Overcurrent protection is usually provided in the form of fuses or circuit breakers. These devices operate when a short circuit, ground fault or an extremely heavy overload occurs. Most overcurrent sources produce extremely large currents very quickly.
Overload Protection
Overload protection is installed in the motor circuit and/or motor to protect the motor from damage from mechanical overload conditions when it is operating/running. The effect of an overload is an excessive rise in temperature in the motor windings due to current higher than full load current. Properly sized overload protection disconnects the motor from the power supply when the heat generated in the motor circuit or windings approaches a damaging level for any reason. The larger the overload, the more quickly the temperature will increase to a point that is damaging to the insulation and lubrication of the motor. Unlike common instantaneous type fuses and breakers, overload devices are designed to allow high currents to flow briefly in the motor to allow for: Typical motor starting currents of 6 to 8 times normal running current when starting.
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Short duration overloads such as a slug of product going through a system. If the motor inlets and outlets are covered by a blanket of lint or if a bearing should begin to lock,excessive heating of the motor windings will overloadthe motors insulation which could damage the motor. The overcurrent device will not react to this low level overload. The motor overload device prevents this type of problem from severely damaging the motor and also provides protection for the circuit conductors since it is rated for the same or less current as the conductors. Overload protection trips when an overload exists for more than a short time. The time it takes for an overload to trip depends on the type of overload device, length of time the overload exists, and the ambient temperature in which the overloads are located.
When the level of current in the circuit reaches a preset value, the increased magnetic field opens a set of contacts. Electromagnetic overload relays operate on the magnetic action of the load current flowing through a coil. When the load current becomes too high, a plunger is pulled up into the coil interrupting the circuit. The tripping current is adjusted by altering the initial position of the plunger with respect to the coil.
Installed equipment often includes medium and/or low voltage AC switchgear, DC switchgear, metal enclosed Bus Duct, power transformers, rectifiers, metering, battery systems, SCADA panels, UPS systems and relay & control panels.
Power Control Centre is used for distribution and control of various power source used in industry. Normally Power Control Centers is installed near power source hence fault level is high. It is designed to suit fault level of 50KA or 65 KA for 1 sec. Busbar system in Power Control Centers are designed to suit the fault level as well as temperature rise to 40c above ambient. Ample space
8 is provided for cable termination. Various protections viz short circuit, overload, earth fault, under voltage etc are provided to protect source and equipment.
Main Power Control Center PCC (Power Control Center) is the Main Panel of every industry. The power from the Transformer through bus ducts is fed into PCC that include the main protection devices for the whole industry like Air circuit breakers, Fuse switch units etc. It includes the Main bus bar of the whole system. All the main protections are provided in this panel. From this panel the power is distributed to the various sub-distribution panels, Motor control centers and Feeder pillars.
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The circuit breaker has more advantage than a fuse. It has a switch which goes off whenever there is extra current flowing through it. After each break, the switch has to be made on and thus continues its normal operation. There is no need of a reinstallation. A simple circuit breaker consists of the following components. Switch Electromagnet / bimetallic strip Stationary Contact Moving Contact Catch Upper and lower terminal The switch is connected to the electromagnet with the help of a catch arrangement. In some cases a bimetallic strip is also used. The hot wire is connected to both the ends of the switch. During its normal working, the switch will be in the ON position. Thus, there occurs a closed circuit where the current flows from the lower terminal to the electromagnet and then through the stationary contact and out of the circuit through the upper terminal. The moving contact will be connected to the stationary contact. If an electromagnet is used, an electromagnetic force is created when the electricity is passed through it. When current value becomes high, an electromagnetic force is produced which forcedly pulls down the metal lever connected to the switch. Thus the connection between the moving contact and stationary contact stops causing termination of electricity flow. Take a look at the exact working of circuit breaker when the switch is in the ON and OFF positions. If a bimetallic strip is used the passage of a high current actuates a thin strip to bend which in turn moves the metal lever. After the circuit breaks, the working of the circuit breaker can be restored by turning ON the switch.
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Circuit Breaker in OFF position The circuit breaker may be divided into several sub connections. A main fuse box panel may be installed, which includes any smaller circuit breakers which may include living rooms, upstairs, downstairs and so on.
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Relay Design The diagram shows an inner section diagram of a relay. An iron core is surrounded by a control coil. As shown, the power source is given to the electromagnet through a control switch and through contacts to the load. When current starts flowing through the control coil, the electromagnet starts energizing and thus intensifies the magnetic field. Thus the upper contact arm starts to be attracted to the lower fixed arm and thus closes the contacts causing a short circuit for the power to the load. On the other hand, if the relay was already de-energized when the contacts were closed, then the contact move oppositely and make an open circuit. As soon as the coil current is off, the movable armature will be returned by a force back to its initial position. This force will be almost equal to half the strength of the magnetic force. This force is mainly provided by two factors. They are the spring and also gravity. Relays are mainly made for two basic operations. One is low voltage application and the other is high voltage. For low voltage applications, more preference will be given to reduce the noise of the whole circuit. For high voltage applications, they are mainly designed to reduce a phenomenon called arcing.