Which MV motor starter to choose?

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

Network

starter

Motor

Load

The MV starter and motor are the links between the electrical network and the mechanical load
E&S - Tony Narusevicius - 20-09-2005 - English

The motor starter must be designed to limit the constraints to the network, the motor and the load

Network

Protection

Motor

Load

Overcurrent Thermal (It) rotor Thermal (Pt100) stator

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

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

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

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

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

The most common motor: asynchronous motor

phase 2 phase 1 phase 3

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

120

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)

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

Influence of the service voltage on the motor torque

Torque V"s > V's

V's >Vs starting torque Vs

acceleration torque

Ns

N (speed)

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

Asynchronous motor
single cage rotor starting torque maximum torque starting current low from 0.6 to 1 Tr around 2 to 2.2 Tr double cage deep slot rotor motor slightly higher from 0.8 to 1.2 Tr around 2 to 2.2 Tr (slightly higher for deep slots)

from 4.5 to 5.5 Ir

from 5 to 6.5 Ir

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

these motors are ideal for intensive use and hazardous environments

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

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.
Rr ' > Rr > R= rotor resistance

T max

Ts

T load

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

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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

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Load torque curves of machines

compressor

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

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Starting conditions:
motor torque must always be greater than the load torque

the motor does not start

the motor starts

running point

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

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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

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Direct stator starting on full voltage (FVNR)

Network

Protection

Motor

Load

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)

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

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Reduced voltage by reactance

Network

Protection

L1

Motor

Load

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
Tmax T L1shunted Id/In

I
I L1shunted

4
T with L1 2 2 I with L1

Tr
1 In

If(Tr)

resistant torque

N
N1 Nn
E&S - Tony Narusevicius - 20-09-2005 - English

N
N1 Nn
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Reduced voltage by auto-transformer

Ct1

Network

Motor Ct2 Protection Ct3

Load

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.
T/Tn
Tmax 4 2 Id/In

Tr
1 In

If(Tr)

resistant torque

N
N1 N1 Nn
E&S - Tony Narusevicius - 20-09-2005 - English

N
N1 Nn

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Auto Transformer starting Sequence

First stage:
CT1 must be closed before CT2. CT1 and CT2 are closed CT3 is open
CT2

Second stage:
CT1 is opened CT2 remains closed First stage : the motor is starting with reduced voltage.

Third stage:
CT3 remains open
CT3

CT3 is closed
CT2

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.

CT2 remains closed CT1 remains open

CT2

CT1

CT3
M

Third stage: the motor runs at full voltage.

CT1
CT3

CT1 is opened CT2 are andclosed CT3 are closed CT2

M

CT1

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

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Reduced voltage by Soft Starter

Network

Protection

Soft starter

Motor

Load

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

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

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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

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Soft starter setting: current limitation

Network

Protection

Soft starter

Motor

Load

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
fix frequency

T/Tn
Tmax

T=function

( )
U Un

Is/In

I and Torque

limited T= Tn * (In / Il)2

4 2 Tsn Il 2 Limit of the starting current

Tr
1

In

If(Tr)

resistant torque

Tlimited

N
N1 Nn N1 Nn

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

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Soft starter setting: torque control

Network

Protection

Soft starter

Motor

Load

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

I and T
x In
I starter I1

torque control
U starter=> F

N and CT

speed ramp fonction of torque ramp

Un

Nn

In Tn U1 T1

Tn

resistant torque
T1 = k. I1

t
t1

resistant torque
t1

F1

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

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Soft starter: normal setting

Network

Protection

Soft starter

Motor

Load

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.

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

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Soft starter setting: deceleration

Network

Protection

Soft starter

Motor

Load

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.

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

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Starting mode selection table

application
Permanent or quasi permanent process<1/day Frequent starts>1/day Machines requiring high start torque

Starting mode

Controlled Advantages by disadvantages

1 Circuit breaker or 1 contactor Simplicity, less investment On starting: High torque High current inrush High mechanical stress Reduction of current in rush on starting Poor power factor 3 contactors Optimisation of torque and current inrush on starting expensive

Motor with low current inrush or low power

Direct On Line / Full voltage 1 contactor

Pumps fans, Machines starting compressors, with low torque frequent starts

Stator by reactance

Optimisation When starting Stator by of starting current must be autotransformer characteristics reduced, but the necessary starting or soft starter torque maintained Optimisation of high torque The most difficult rotor starting starts characteristics

2 contactors

generally 3 contactors

Small current inrush and high starting torque

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

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Starting mode selection table

yes

- deceleration control ? - the drive between motor and load is able to withstand the mechanical stress of a direct on line start

no no yes yes no

- constant torque with high starting torque as crushers, grinders, mixers ......

Network requirement
- accepts full starting current? - accepts starting voltage drop? -accepts the starting reactive consumption power? - accepts the current oscillation during an open transition? - accepts the harmonics during the starting period
no yes

Investment Increase
no
yes no yes no yes yes

no
yes

no

VSD specific

FVNR

RVAT

RVSS

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

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main protection
overload short circuits thermal protection overcurrent, thermal image, and thermal sensors To protect the motor and the network fuses and instantaneous over-current relay bearing overload temperature simulated by relay thermocople RTD faults give rise to: increased current in the stator earth leakage protection (differential protection) vital to comply with the worker protection protection windings and magnetic circuit zero sequence current relay under-voltage: common protection, prevents the motor on working on overload over-voltage: fluctuations on the network prevents long motor starting and over temperature speed or current protection of the motor against thermal damage mainly for pumps specified by motor manufacturers

Incomplete phase, phase reversal and unbalance insulation fault in the winding stator/ frame under and over voltage incomplete starting or frequent starts locked rotor under power or undercurrent other protection

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

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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)
3300 (1000 m) and below 5000 (1500 m) 10,000 (3000 m)

Voltage
1.00 0.95 0.80

Current
1.00 0.99 0.96

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

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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

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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

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

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