Motorcontrol 13284788078619 Phpapp02 120205155657 Phpapp02

Motor Control Systems
Core Applications
At the end of the presentation we will know the

following:
1.
2.
3.
4.
Definition of motor controllers.

Different types of motor controllers.
How control circuit interacts with different
components to met specific requirements.
The use of motor control for energy
savings.
cole.c/motor_control
8/22/16
ELECTRIC MOTOR
ELECTRIC MOTOR- is an electrical machine that converts electrical
energy to mechanical energy in order to produce work.
Modern civilization is incomplete without electric motors !!!
8/22/16
DEFINITION
A motor controller is a device or group of
devices that serves to govern in some
predetermined manner the performance
of an electric motor.
A motor controller includes a manual or
automatic means for starting and stopping
the motor, selecting forward or reverse
rotation, selecting and regulating the
speed, regulating or limiting the torque,
and protecting against overloads and faults.
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MOTOR CONTROL
SYSTEMS
REQUIREMENT
S
i.e. conveyor,
lift, pump, fan
and others
MOTOR CONTROL
CORE APPLICATIONS
CONVENTIONAL
METHOD USING
ELECTROMECHANICA
L COMPONENTS AND
SYSTEMS
ADVANCE METHOD USING

PLC, MICROCONTROLLER,
SCADA, REMOTE
CONTROLLER
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FULL VOLTAGE STARTER

Full voltage starter is the most common
type of motor starter where the motor is
connected directly across the line.
When started this
way the starting
current will reach
as high as 600%
of its full load
current.
This method of
starting is used
for motors 10 HP
and below.
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FULL VOLTAGE STARTER:

NON-REVERSING
Commonly known as
across the line
method of starting. This
type of starter is used
when controlling motor
in one direction.
* When the start button is
pressed
the
contactor
is
activated closing the main
contact M and causes the motor
to run.
* The auxiliary contact M that is
connected in parallel with the
start pushbutton will hold the
whole rung remain activated
whenever the pushbutton will
return into its original position
after pressing.
RUN
RUN SIMULATION
SIMULATION
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NON-REVERSING
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VARIATION
Depending upon the requirements every circuit may vary
depending upon the application requirements.
For example:
The NC auxiliary contact of the
pressure switch can be
connected in series with the
standard DOL starter in order to
automatically off the motor once
the set value for pressure is
reach.
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REVERSING
Commonly
known
as
forward-reverse method
of starting. This type of
starter
is
used
when
controlling motor in two
directions.
* When the forward F contactor is
activated the motor will put into forward
direction.
* The key for reversing the direction of
the motor is that the lines that supplies
the other contactor (R) L1and L3 is
interchanged.
RUN SIMULATION
* The 2 normally closed contacts that

are connected in series in forward and
reverse rung respectively are called
electrical interlocking. This is to prevent
simultaneous activation of the 2 rungs
that might cause serious damage to the
equipment if happens.
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10
EXAMPLES OF MOTOR
THAT USED REVERSING CONTROL
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11
VARIATION FOR REVERSING

CIRCUIT
LS
LS
The NC contact from the limit switch can be

connected in series with the UP branch of the
reversing circuit to automatically stop the
motor once it reach the desired level.
Similarly the NC contact from the limit switch
can be connected in series with the DOWN
branch
of
the
reversing
circuit
to
automatically stop the motor once it reach
the desired level.
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12
REDUCED VOLTAGE
STARTER
Reduced voltage starter is a type of motor starter wherein the
effect of the starting inrush current is suppressed. This can be
accomplish by the used of sequential switching from the initial to the
final state. Once the motor has come up to some fraction of its fullload speed the starter switches to full voltage at the motor terminal.
Full voltage starting of motors
can produce objectionable
voltage flicker, mechanical
stress to gear boxes or belt
drive systems and create
pressure surges or water
hammer
in
pumping
applications.
Starting a motor at reduced voltage can help reduce or
overcome these problems. Reduced voltage is typically
used for motors 10 HP or more.
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13
REDUCED VOLTAGE STARTING:

WYE-DELTA STARTER
Wye-Delta is an electromechanical way of reducing the
voltage applied (58%) during starting. This can be accomplish
by connecting the motor at Y first during starting (3-5sec)
and changing it to DELTA thereafter.
In 3-phase system:
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14

WYE-DELTA STARTER
RUN SIMULATION
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15

WYE-DELTA STARTER
T6
CIRCUIT OPERATION IN
WYE-DELTA STARTING
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16
VARIATION OF
WYE-DELTA STARTER
float
NC auxiliary contact for float control relay can be installed in series with the main
contactor to automatically control the pump operation.
The pushbuttons are replaced with selector switch since the latched circuit
cannot be automatically activated once deactivated.
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AUTOTRANSFORMER
Once the start button is pressed

the contacts from S and Y
contactor will be close, thus
reducing the starting current at
the desired level.
After 3-5 seconds these contacts
will open followed by the closing of
contacts from contactor R.
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18

AUTOTRANSFORMER
Autotransformer starting method is commonly used in large submersible pump
motors. Just like wye-delta the effect of starting inrush current is suppressed.
BENEFITS:
1. Submersible pumps
commonly have 3 leads out,
making it unfit for wye-delta
starting.
2. If there are 6 leads out
submersible pump available
then it is economically
impractical to use wye-delta
since it follows that an
additional three conductors
are needed to power up the
motor.
3. Other applications where the
starting voltage is to be
reduced lower than 58% then
autotransformer can be used
since wye-delta starting is
fixed at 58%.
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19
PART WINDING
PWS can be accomplished by first energizing the half of the motor coil for
at most 3 seconds then followed by the energization of the overall coil.
Unlike the wye-delta starting that is used for accelerating the motor or
provide reduced torque, PWS on the other hand mainly used to minimized
voltage drop that keeps the nearby lights free from flickering.
RUN SIMULATION
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20
SOFT STARTER
Soft starter is a solid state device used with AC electric
motors to temporarily reduce the load and torque of the motor
during startup. This reduces the mechanical stress on the
motor and shaft, as well as the electrodynamic stresses on the
attached power cables and electrical distribution network,
extending the lifespan of the system.
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21
SOFTSTARTER
TYPICAL POWER CIRCUIT
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22
SOFTSTARTER
TYPICAL POWER CIRCUIT
Auxiliary SCR output

contact 13-14 is
used for controlling
the start/stop
function directly
wired from the
control circuit to the
soft starter.
Auxiliary SCR output
contact 23-24 is
activated when the
ramp up time has
elapsed causing the
by-pass contactor to
be activated.
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23
COMPARISON
DIRECT
DIRECT ON
ON LINE
LINE
WYEWYE- DELTA
DELTA
SOFT
SOFT STARTER
STARTER
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24
VARIABLE FREQUENCY
DRIVE
drive
A variable-frequency
(VFD) is a solid state device for
controlling the rotational speed of
an
alternating
current
(AC)
electric motor by controlling the
frequency of the electrical power
supplied to the motor.
Where:
= synchronous speed (RPM)
f
= frequency (Hz)
P
= number of poles
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25
VARIABLE FREQUENCY
DRIVE
VFD system
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26
VARIABLE FREQUENCY
DRIVE
VFD can be controlled by
many ways such as:
Button or attached HMI
Discrete input from PLC
or other remote
controlled relay
Potentiometer for
remote control
operation
PID signal from
transmitters and
transducers
Computer ports thru
RS-485
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27
VFD CONTROL
VFD is controlled manually by keypad

or attached HMI.
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28
VFD CONTROL:
DIRECT MANUAL EXAMPLE
CAN SEAMER
TIN COIL CUTTING LINE
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29
VFD CONTROL:
REMOTE CONTROL
For remote control manual operation:
For automated operation:
A separate remote control unit using

toggle switch, pushbutton and
potentiometer can be installed to
control the operation of the VFD.
A
remote
control
unit
and
feedback
control
using
transmitters
and
transducers
forming close loop system is installed
to control the operation of the VFD.
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30
VFD WITH REMOTE

CONTROL
Discrete output from PLC

can be connected directly
to VFD.
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31
APPLICATION EXAMPLE FOR

VFD WITH REMOTE CONTROL
BOILER CONTROL
ROOM
DEVICE LOCATION
8/22/16
32
VFD CONTROL:
AUTOMATED CLOSE LOOP SYSTEM
--- 4-20 mA or 0-10 VDC
AUTOMATING VFD SYSTEM CAN BE USED FOR ENERGY

SAVING PURPOSES
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VFD CONTROL: AUTOMATED CLOSE LOOP SYSTEM
Temperature
sensor
HMI
motor
PLC
Temperature
controller
-analogue signal feedback: 4-20 mA or 0-10 VDC
The VFD can be activated manually thru HMI or from PLC if the motor operation is dependent on the
other parts of the industrial processes.
The function of the analogue feedback signal is to keep the speed of the motor at the set value.
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34
MOTOR CONTROL FOR ENERGY SAVING APPLICATIONS:

AIR BLAST FREEZER
In air-blast freezer where the fan are used to
induced cool air to the products.
Once the cool air are uniformly distributed all
throughout the products, the temperature will tend
to go down until the temperature will reach into the
saturated level (e.g. -35 degree C ).
When the temperature will go beyond its required
value, it is already useless as far as the
requirement is concern.
The fan that are continuously running at full speed
once the temperature requirement is met
manifests waste of energy.
Solution:
The temperature sensor will detect that the temperature level.
The sensor will send feedback to the VFD thru temperature
controller.
The VFD now will regulate the speed of the motor so as to met
the required temperature.
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35
MOTOR CONTROL FOR ENERGY SAVING APPLICATIONS:

GRAIN DRYER
In grain dryer the fan are used to induced hot air to
the products.
The size of the drying bin is fixed and the fan is
designed for that size.
Sometime the volume of the production is
relatively lower than the drying capacity.
If the fan is operated at full speed it could result
into substandard products.
The conventional solution for this problem is the
installation of valve in the drying bin that would
served as a passage to the excess hot air.
The evacuated hot air manifests waste of energy.
Solution:
The temperature sensor will detect that the temperature level.
The sensor will send feedback to the VFD thru temperature
controller.
The VFD now will regulate the speed of the motor so as to met
the required temperature.
8/22/16
36
HOW VFD REDUCES ENERGY CONSUMPTION
AFFINITY LAW OF
CENTRIFUGAL LOADS:
REMEMBER THAT:
Nsyn = (120 x f ) / P
P2/P1 = (f2/f1)3
f = (P x Nsyn ) / 120
P2= (f2/f1)3 X P1
From the formula it is clear that an 80% speed reduction

of the motor driving centrifugal loads such as pumps
and fans can make 50% reduction of electrical
consumption.
SAMPLE
8/22/16
37
THANK YOU
VERY MUCH
8/22/16
38

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Motor Control Systems

At the end of the presentation we will know the

Definition of motor controllers.

ADVANCE METHOD USING

FULL VOLTAGE STARTER

FULL VOLTAGE STARTER:

FULL VOLTAGE STARTER:

FULL VOLTAGE STARTER:

* The 2 normally closed contacts that

VARIATION FOR REVERSING

The NC contact from the limit switch can be

REDUCED VOLTAGE STARTING:

REDUCED VOLTAGE STARTING:

REDUCED VOLTAGE STARTING:

REDUCED VOLTAGE STARTING:

Once the start button is pressed

REDUCED VOLTAGE STARTING:

TYPICAL POWER CIRCUIT

TYPICAL POWER CIRCUIT

Auxiliary SCR output

VFD is controlled manually by keypad

TIN COIL CUTTING LINE

For remote control manual operation:

For automated operation:

A separate remote control unit using

VFD WITH REMOTE

Discrete output from PLC

APPLICATION EXAMPLE FOR

--- 4-20 mA or 0-10 VDC

AUTOMATING VFD SYSTEM CAN BE USED FOR ENERGY

VFD CONTROL: AUTOMATED CLOSE LOOP SYSTEM

-analogue signal feedback: 4-20 mA or 0-10 VDC

MOTOR CONTROL FOR ENERGY SAVING APPLICATIONS:

MOTOR CONTROL FOR ENERGY SAVING APPLICATIONS:

HOW VFD REDUCES ENERGY CONSUMPTION

From the formula it is clear that an 80% speed reduction

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