Objective
At the end of the lecture students will be able to describe the working principles of motor starters and various protection devices
Motors
A motor is basically a generator running in reverse. A current is passed through the coil, producing a torque and causing the coil to rotate in the magnetic field. Once turning, the coil of the motor generates a back emf, just as does the coil of a generator. The back emf cancels some of the applied emf, and limits the current through the coil.
3
Motor
DC AC AC Motor Induction motor Synchronous motor Wound rotor motor Operate based on Speed (S)= 120f/p F-Frequency P-Number of poles
Control
Control: getting motors to do what you want them to What you want to control = what you can control
For DC motors:
speed
voltage
windings resistance
R
S
N S
back emf
1.
Induction motor drawn 5-8x full-load current (FLC) when starting 2. Due to maximum flux cutting rate (s = 100%) in rotor- creating large induced rotor currents 3. Supply power factor very low i.e. 0.2 lagging at starting, 0.5 lagging on no-load & 0.85 lagging on full-load 4. This starting surge current reduces as motor accelerates up to rated speed 5. Operating at light loads with low power factor inefficient as supply current higher causing higher IR (copper) losses 6. To improve - reduce supply voltage for light loads motor 7. Achieved with electronic voltage controller i.e. soft-starter and/or energy manager - match supply voltage to start-up & load conditions
8. 9.
This will maintain operating power factor as high as possible - minimise supply current & power losses Most induction motors have Direct-on-Line (DOL) - inexpensive & simple to operate & maintain provided current surge not cause heating damage to motor When larger motors started by DOL can cause voltage dip due to large starting current May result in malfunction of others - lighting dip & flickering effects To limit, motors started at reduced voltage- full supply reconnected when accelerated close to rated speed - star-delta, auto transformer & electronic "soft" starter
1000
100
Motor Characteristics
Normal Operating Current
10
Time in Seconds
1 0.1
Inrush Current
0.01 1
Current in Amperes
10
100
1000
1000
1000
100
100
300 % Overload
Short Circuit
10
10
Time in Seconds
0.1
0.01 1
Time in Seconds
1 0.1 0.01 1
Current in Amperes
10
100
1000
Current in Amperes
10
100
1000
COMPARISON OF STARTERS
600 DIRECT ON LINE STARTING
Current %
400 AUTO TRANSFORMER STARTING STAR DELTA STARTING Slip Auto transformer on % 60% 0
200
0 100
Contactor
Performing switching action to connect/disconnect power supply to motor. Electromagnetically operated 3-pole switch initiated from local, remote stop/start push buttons. If current above rated,
Direct on line
Simple arrangement, used for majority induction motor Motor directly switched onto 3 phase AC power supply lines Further circuit additions remote control & reversing (required extra contactor) Short duration but large starting current Acceptable provided voltage dip < 10~15% during starting For larger motor - unacceptable voltage dip at bus-bars malfunctions of other consumers & possible drop out of supply contactors If prolonged cause supply line & generator protection to trip
Manual closing of fused isolator Q1 Control circuit voltage available (e.g. 110V from control transformer) Closing of line contactor KM1 KM1 contactor holds-in Press start button I (local or remote) Auxiliary contact on KM1 latches contactor Remote indicator lamp on Press stop button O (local or remote) on overload the OCR trips out the stop button OCR must be manually reset (after thermal time delay)
Star delta
If motor stator winding is star connected, only 1/3 of starting current required if motor start with delta connected For small motors operated by manual c/o switch For large motors - phase windings automatically switched using timing controlled contactors At initial starting, motor wont rotate, thus no mechanical output produced Therefore, current taken by the motor will determine by supply voltage & impedance of motor phase windings
Closing contact of KM1: star connection Press start button S2 to close KM1 Closing of KM2: motor supply KM1 closes KM2
Opening of KM1: star connection opens hold in of KM1 KM2 by KM2 auxiliary Closing of KM3: delta connection Opening of KM1 by KM2 auxiliary Closing of KM3 by KM1 auxiliary
KM2 & KM3 contactors drop out, motor Stop by S1 button or OCR trip F1 stops
Note: KM2 has a pair of auxiliary contacts with a time delay action (typically 40ms) between the operating of the N/C and the closing of the N/O contacts.
Ratio of
I L (Y ) I L()
3.Z 1 = = 3 3.VL Z
VL
Auto transformer
Starting large motor with prolong run-up period demand very high current surge from supply generator even for few seconds Will causes severe voltage dip - affects other loads Reduced voltage starting will limit starting surge current One method step it down using transformer When motor accelerated up to almost rated speed, then reduced voltage will resume to normal Special transformer uses one winding for input & output Thus, cheaper, smaller & lighter than equivalent doublewound transformer Meant for operation of short starting period only Only applicable to large motor drives due to initial cost
Power circuit operation Manual closing of fused isolator Q1 Closing KM1: star connection of transformer Closing KM2: motor supply via transformer Opening KM1: star connection opens Closing KM3: direct supply to motor
Control circuit operation Control circuit voltage available (e.g. 110V from control transformer) Press start button S2 to close KM1 Interlocking of KM3 by KM1 Closing KA1 by KM1 Closing of KM2 by KA1 Hold in of KM2 Opening KM1 by KA1 (after time delay) Closing KM3 by KM1 Interlocking KM1 by KM3
(Note the mechanical interlock of KM1- Hold in of KM3 KM3) Opening of KM2 by KA1 KM3 contactors drop out, motor stop Stop by S1 button or OCR trip F1
Conclusion
DOL starter - simple & cheap but causes large starting surge Star delta starting reduces surge but more complex require 3 contactors & timer Auto transformer - can arranged to match motor surge current & run-up period with suitable voltage but the most expensive one
e = ke = k I
R V e
DC motor model
e = ke = k I V = IR + e
How is V related to ?
Istall = V/R
R V e
R V= + ke k
- or -
V =- R + ke k ke DC motor model
Speed is proportional to voltage.
V ke
torque
kV R
V ke
torque
kV R
stall torque
V ke
max speed
power output
torque
kV R
stall torque
Motor specs
003S
006S
012S
024
-------------------------nominal supply voltage armature resistance maximum power output maximum efficiency no-load speed no-load current friction torque(oz-in) stall torque velocity constant back EMF constant torque constant armature inductance
-------(Volts) (Ohms) (Watts) (%) (rpm) (mA) .010 (oz-in) (rpm/v) (mV/rpm) (oz-in/A) (mH)
-------3 1.6 1.41 76 12,000 30 .011 .613 4065 .246 .333 .085
-------6 8.6 1.05 72 10,600 16 .013 .510 1808 .553 .748 .200
ke
Back to control
Basic input / output relationship: R V= + ke k
We can control the voltage applied V. We want a particular motor speed .
PWM
PWM -- pulse width modulation
Duty cycle:
The ratio of the On time and the Off time in one cycle Determines the fractional amount of full power delivered to the motor
Motor
actual speed
V Motor
actual speed
Speed control:
Stator voltage control Supply frequency control Rotor resistance control Pole changing
VSD
Conventional control of supply frequency and terminal change of phase to minimize losses counter current /pluging+ regenerative +dynamic Development in speed and torque control From ward leornard system -> thyristor controlled DC drive ->PWM AC variable voltage regulation ->variable frequency converter-> AC VSD or inverter Cost effective method of speed control+ application to high power+relibaility+maintainability+save energy+ improve efficiency+ match speed and torque of drive with process drive Backdrop- complexity
Component Motor drive control unit-power source to motor, increase and decrease motor set point at operator panel+ feed back loop give the driv the actual speed+Power modulation control the speed , torque and power along with direction of motor and machine- i.e converter, inverter, cycloconverter. +sensing unit +operator unit
Protection
Motor enclosure Totally enclosed , non ventilation Splash proof type Totally enclosed fan cooled Drip proof type Name plate- rating, supply , connection ,frame type and size,permisible temperature,rpm, enclosure type,# of pole.
1. Short-circuit protection of stator windings 2. Stator-overheating protection 3. Rotor-overheating protection 4. Under voltage protection
Motor Protection
Protection
Measurement Temperature Voltage and current Insulation resistance winding resistance Vibration Speed
Testing: No load test Full load test k
Failures: Insulation failure Rotor bar failure Mechanical problem Maintenance Periodic inspectionAccurate shaft alignment or belt tension Check motor heating@ heating- check and clean air filter Keep motor clean and free from dirt Keep motor dry - Check for dampness around and inside motor Check bearing regularly- lubrication at right quantity Vibration analysis- of motor and coupling
Safely & interrupt prospective short circuit fault current expected in circuit Will trips but can be reset & reused Link mechanism provided, closes main contacts under spring pressure & wipes the surface of fixed contact points - ensuring good electrical contact Main contact open rapidly with snap action Resulting arc transferred to special arcing contacts above the main contact Arc chutes with arc splitter quickly stretch & cool the arc till it snaps Circuit breaker is open when the arc quenched
Circuit Breaker
Protect circuit from damage faults & over current Designed to blow rapidly before circuit damage takes place Many types and sizes, marked with size of steady current can be carried without blowing - fuse rating Transparent casing
Tinned wire copper
Fuse
Brass cap
Fuse Rating
Important correct rating for normal current flowing in circuit it protects Lower rating - every time switch on, fuse will blow Higher rating promoting positive dangerous circuit with over current flowing without blowing fuse - overheat & can cause fire If fuses blow, must replaced by same type & same rating Position - between supply and the circuit fuses removal means total isolation for the circuit Two main types:
Cartridge fuse High rupturing capacity (HRC) fuse
There are four parts in every relay: 1. Electromagnet 2. Armature that can be attracted by the electromagnet 3. Spring 4. Set of electrical contacts
UV relay coil
Generator
Normal Condition
1.4 A
What happened?
0A
1.4 A
M
40 C
2.4 A
(173%)
2.4 A
(173%)
Single phasing
Occurs when one of three back-up fuses blows or if one of contactor contacts is open-circuited Effect current increase in two remaining lines Cause noisy motor uneven torque produced in rotor Will detect by OCR unequal heating of bi-metal strips causes differential movement, initiate OCR to trip motor contactor For star connected motor phase & line currents are equal, thus OCR has no problem in sensing correct winding current For delta connected uneasy task, therefore, normally line current will divides phasorally between 2 phases of motor windings
I PH =
IL 3
= 0.577 I L
Single phasing
% of rated FLC
IL2 and IL3 IA and IB IC
60 70 100
62 79 129
AC Input
PWM Signal
BLDC Motor
Power Management
IPM Module
Others
Feedback Signal (Speed / Positon)
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