IEEE-IAS 2012.02.18 Presentation - Motor Starting Techniques
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Transcript of IEEE-IAS 2012.02.18 Presentation - Motor Starting Techniques
IEEE - IASMotor Parameters &
Starting
By: James S. Nasby -- Columbia Engineering
Topics to be CoveredI. Induction Motors –
General
II. Electrical Power Supply
III. Induction Motor Parameters
IV. 3Ø Motor Starting Types (8+1)
V. 3Ø Motor Running Types (3)
VI. Common Motor Wiring Types (14)
VII. Installation Considerations
I. Motors – GeneralMotor Types
Induction Motors Three Phase Non-Salient Pole Motors:
Usually Squirrel Cage Rotor Motors -but- can be Wound Rotor (Slip Ring) Induction Motors
Design Type: NEMA Design “B”Normal Starting TorqueNormal Starting Current (KVA)
Synchronous, Single Phase & D.C. Motors Not Covered
I. Induction Motors General Definitions
Motor Poles – Even Numbers (2, 4, 6, etc.) Full Load Speed – Synchronous Speed - Slip Starting Region – Basically Fixed
Impedance Running Region – Energy Converter Torques:
Stall = Locked = Zero Speed Torque
Pull-up Torque
Breakdown Torque
Rated Torque Starting Amps, KVA & Locked Rotor Code Motor Housings TEFC & ODP
Motor Starting Region – cont’dMotor Torque Curve
Motor Torque and Pump Torque Curves
II. Electrical Power Supplies
Power Sources - Mains
Types of Power Source– Three Phase A.C.
Power Source Characteristics
(Parameters)– Voltage (Utilization Voltage) -at- – Low voltage or Medium Voltage– Frequency – 50 Hz or 60 Hz– Starting Voltage Drop -vs- Starter
– Running Voltage Drop -vs- Motor
Power Supply Characteristics – cont’d
- Power Quality - Source Capacity - Weak or Stiff Source
– Starting Voltage Drop (15% of Controller Rated)
– Running Voltage Drop (5% of Motor Rated)– Method of Calculating - NEMA ICS-14– Gen-Sets - Frequency & Voltage
Voltage Balance (Amount of Imbalance)- Small Voltage "Unbalance" = Large Current
Imbalance. See NEMA MG-1, part 14.35.- Typical 6% to 10% Current Imbalance for each
1% Voltage Imbalance per MG 1-14.35.5. - This is due to the motor trying to bring up the
low voltage leg (acting as a generator).
Voltage Harmonics (Heats Windings)
Power Factors - Affected by Motor
III. Induction Motor ParametersGeneral Motor Characteristics Induction Motor Types
– Wound Rotor Motor
(Slip Ring Motor)E.g.: Rotary Transformer
– Squirrel Cage Motor = Ditto– But with Slip Rings Shorted
Frequency – 50 Hz -vs- 60 Hz NEMA Design Type “B” (MG-1)
(Normal Starting Torque, Starting Current, Breakdown Torque, and Slip)
NEMA Design Types
Standard Three Phase
Induction Motors are
NEMA Design “B”
( Rated Full Load Torque)
Rated | Speed (RPM)
Induction Motors - cont’d Motor Parameters - Electrical
Locked Rotor Code (KVA per Hp) Service Factors
– Typically 1.15 Maximum Allowed– Often Higher for Smaller Motors– Usually 1.0 Max. when used with VFD's and often with TEFC motors.
Service Factor (S.F.) -vs- Ideal Conditions– Max. Temperature (40 °C Max.) -and-– Max. Altitude (3,300 ft /1,000 m Max.) -and-
– Max. Voltage Imbalance (1% Max.)
Motor Parameters – cont’d Abbreviations & Acronyms Motor Currents
– FLA = Motor Full Load Amperes– FLC = Motor Full Load Current = FLA– LRC = LRA = Locked Rotor Current (Amps)– SFA = Service Factor Amps – Locked Rotor Code* – Codes F & G
Common
*May be Much Higher for Smaller Motors and for Energy Efficient Motors
Power Factor (PF) – Real -vs- ImaginaryStarting PF = 30% / 40% TypicallyRunning PF = 85% down to 8.0% from Full Load to No Load, Typically
Motor Parameters – cont’d Motor Current Curve
Motor Current -vs- RPM Curves
Rated Running Current = 100%
Induction MotorLocked Rotor Codes
Maximum Allowed Motor Locked Rotor Codes per NFPA-20:
Code "F" for 15 Hp & up -or-5.0 thru 5.59 KVA/Hp = approx. 540% FLA
Code "G" for for 15 Hp & up5.6 thru 6.3 KVA/Hp = approx. 600% FLA
Code "H" for 5 thru 10 Hp(up to 7.1 KVA/Hp = approx. 685% of FLA)
Code "J" for 5 Hp only(up to 8.0 KVA/Hp = approx. 772% of FLA)
Induction Motor Locked Rotor Codes
Table M-02 -- Motor Locked Rotor Code KVA Data and Allowed Horsepowers
"F" "G" "H" "J" Code Letter
Min. Max. Min. Max. Min. Max. Min. Max.
KVA per Hp 5.00 5.59 5.60 6.29 6.30 7.09 7.10 7.99 LRA/FLA 482% 540% 540% 608% 608% 685% 685% 772% Allowed Hp 15 Hp and up 15 Hp and up 5 thru 10 Hp 5 Hp only
Note: The LRA/FLA ratios shown are approximate for illustration only.
Table M-03 -- Maximum Motor Locked Rotor Currents
Motor Voltage - 60 Hz values Rated
Horsepower
Code
Letters 200 Vac 208 Vac 230 Vac 460 Vac 575 Vac
5 F - J 106 102 92 46 37 7.5 F - H 147 142 128 64 51 10 F - H 186 179 162 81 65 15 F - G 267 257 232 116 93 20 F - G 334 321 290 145 116 25 F - G 421 405 366 183 146 30 F - G 499 480 434 217 174 40 F - G 667 641 580 290 232 50 F - G 833 801 724 362 290 60 F - G 1,001 962 870 435 348 75 F - G 1,249 1,201 1,086 543 434 100 F - G 1,668 1,603 1,450 725 580 125 F - G 2,088 2,008 1,816 908 726 150 F - G 2,496 2,400 2,170 1,085 868 200 F - G 3,335 3,207 2,900 1,450 1,160 250 F - G 4,198 4,036 3,650 1,825 1,460 300 F - G 5,060 4,865 4,400 2,200 1,760 350 F - G 5,865 5,639 5,100 2,550 2,040 400 F - G 6,670 6,413 5,800 2,900 2,320 450 F - G 7,475 7,188 6,500 3,250 2,600 500 F - G 8,338 8,017 7,250 3,625 2,900
Note: The 460 Vac LRA values are from NFPA 20 Table 6-5.1.1. Others are calculated using voltage proportion.
Induction Motor Locked Rotor Currents
Motor Parameters – cont’d Motor Stalled (Locked Rotor) Power Factor = Approx 40%
Motor Parameters – cont’d Motor Theory and Formulae
Purpose – Electrical to Mechanical Energy Conversion
– Motor Starting Region (Rotary Solenoid)– Running Region (Energy Converter)
Motor Torque & Motor Current Draw -vs- Speed Curves A‑T‑L‑Starting
(Basic Motor Characteristics)– Power Factor & Phase Angles– Efficiencies
Motor Starting -vs- Motor Running Regions
Motor Starting -vs- Motor Running Regions
Motoring Region
Starting Region
Motor Parameters – cont’d Motor Torque Curve
Motor Torque and Pump Torque Curves
Motor Parameters – cont’d Motor Torque Curve
Motor Torque and Pump Torque Curves
Motor Parameters – cont’d Motor Current Curve
Motor Current -vs- RPM Curves
Rated Running Current = 100%
Motor Parameters – cont’d Motor Current Curve
Motor Current -vs- RPM CurvesNote where 115% S.F. is on vertical axis.
Rated Running Current = 100%
Motoring RegionStarting Region
100% (FLA)
Motor Theory and Formulae
Motor Starting RegionFor a Motor at Stall, Motor Impedance
is Constant. So: I = E / Z (Ohm’s Law)
Current is Directly Proportional to Motor Voltage. I.E.:
Motor Current = Voltage / Impedance
Power Factor (P.F.) is Typically 30% to 40% at Stall and for most of the starting region. Important for starting voltage drop (115%) calculations.
Motor Theory and Formulae
Motor Starting Region – cont’d
In the Starting (Accelerating) Region:Torque is Proportional to the Square
of the Applied Motor Voltage T = K1 x V2 -or- Since Current is proportional to Voltage (see above): T = K2 x I2
Thus: Torque is also Proportional to the Square of the Motor Current Relevant for reduced starting torques
Motor Theory and FormulaeMotor Starting Region – cont’d
Example of Starting Torque Proportional to the Square of Applied Motor Voltage.
E.G. 50% Volts = 25% of Rated Stall Torque.
Motor Theory and Formulae Motor Running Region
Motor Running Region (Energy Converter):Mechanical Power is Torque x Speed:
Pm = K3 x Tq x RPMMotor Torque is Whatever the Load
RequiresElectrical Power Input is:
Pe = Pm + Motor Losses = Pm / EfficiencyBut, Electrical Power Input is also given as:
Pe = K4 x V x Ireal (Volts x Real Current)So: Ireal = K5 x Pe / VoltsThus Motor Current is Inversely Proportional
to Motor Voltage with a Running Motor
Motor Running -vs- Motor Starting Regions
Rated Torque (100%) times Rated Speed (E.g. 1750 RPM) yields Motor Rated Horsepower.
IV. Motor Starting General ‑ Overview – Types of
Reduction– Voltage Reduction: Wye–Delta, Soft Start,
and Autotransformer– Current Reduction: Primary Impedance
(Primary Resistor, Primary or Neutral Reactor)
– Motor Impedance (Wound Rotor) Two Specialty Types
– Medium Voltage – Four Common Types: A-T-L, Primary Reactor, Neutral Reactor -and- Autotransformer
– Low Voltage - Wound Rotor (Not U.L. Listed)
Motor Starting - cont’d
Eight (+1) Common Low Voltage Starting Types:
Across‑the‑Line (A‑T‑L or Direct‑On‑Line) Part Winding (Half Winding) Start Primary Resistor Start Primary (or Neutral) Reactor Start Wye‑Delta (Star‑Delta) ‑ Open Transition Wye‑Delta (Star‑Delta) ‑ Closed Transition Soft Start / Soft Stop (SCR Phase
Modulation) Autotransformer VFD Ramp-up (and Ramp-down on some)
Motor Starting – cont’dAcross-the-Line (Direct On Line)
Note absence of Motor Overload (O/L) relay.
FullVoltageStart ------------Across-the-Line
Motor Starting – cont’dAcross-the-Line (Direct On Line)
Motor Starting – cont’dPart Winding Start
Note: The Motor Must be Wound Specifically for Part Winding Starting.
Part Winding Start
Motor Starting – cont’d
Part Winding Start
Motor Starting – cont’dPrimary Resistor Start
Note: Starting KW higher than ATL starting.
Motor Starting – cont’dPrimary Resistor Start
Note: 65% Resistor Impedance is
1.24 - 0.40 = 0.84 pu
Motor Starting – cont’dPrimary Reactor Start
Primary Reactor Start
Motor Starting – cont’dPrimary (or Neutral) Reactor Start
Note: 65% Reactor Impedance is
1.54 – 1.00 = 0.54 pu
Motor Starting Torque Comparison
Curves B, C & D are at 65% Motor Starting Voltage(Reference Source Credit on Next Slide)
“0”“0”
Motor Torque Comparison – cont’dA=ATL, B=A.T., C=Pri. Res., D=Reactor
Gerhart W. Heumann (G.E.), “MagneticControls of Industrial Motors”, Wiley & Sons.
Motor Starting – cont’dPrimary (or Neutral) Reactor Start
Wye-Delta Open Transition
Motor Starting – cont’dWye-Delta Open Transition
LPM Module = Leading Phase Monitor®
First Half Cycle Offset Waveforms
2.83 x LRA = 6 x 2.83 x FLA = 17.0 x FLA Maximum Theortical This curve shows starting a motor
which still has BACK EMF (voltage) present.
Motor Starting – cont’dWye-Delta Open Transition
Motor Starting – cont’dWye-Delta Open Transition
Motor Starting – cont’dWye-Delta Open Transition
Motor Starting – cont’dWye-Delta Transition Hazard
ClosedLeading
Lagging
Motor Starting – cont’dWye-Delta Closed Transition
Wye-Delta Closed Transition
Motor Starting – cont’dWye-Delta (Open or Closed Xtn.)
Wye-Delta Starting; Truths and Myths
Page 1 of 4
Wye-Delta Starting; Truths and Myths
Page 2 of 4
Wye-Delta Starting; Truths and Myths
Page 3 of 4
Wye-Delta Starting; Truths and Myths
Page 4 of 4
Motor Starting - cont’dSoft (Solid State - SCR) Start
Soft Start (Solid State - SCR)
Motor Starting - cont’dSoft (Solid State - SCR) Start
Motor Starting - cont’dAutotransformer Start
Autotransformer Start
Motor Starting - cont’dAutotransformer Start
Motor Starting Characteristics
Parameter Chart Fire Pump Starting Type Characteristics - for - Electric Fire Pump Motors and Controllers
Starting Characteristics (at Stall) -- Typical Values -for- Fully Load Pump (1) Starting Starting Starting Accelerate Motor Motor Amps Amps Starting Power Starting Full Load Type Contactors Closed & KVA & KVA Power % F.L. Torque to Starting Type Note Note (3) Transition % LRA % FLA Factor Note (4) % ATL Full Speed Notes Across-the-Line Any 1 N/A 100% 600% 40% 240% 100% Yes (a)
Part Winding Special (2) 2 Yes 65 390 40 156 48 Usually (b) Primary Resistor Any 2 Yes 65 390 80 314 42 Yes (c)
Primary Reactor Any 2 Yes 65 390 28 111 42 Yes (c) Neutral Reactor 6/12 Lead 2 Yes 65 390 28 111 42 Yes (c)
Wye-Delta Open 6/12 Lead 3 No 33/100 200/600 40 80/240 33 No (d) Wye-Delta Closed 6/12 Lead 4 Yes 33/100 200/600 40 80/240 33 No (d)(e)
Soft Start/Stop Any 1/2 Yes 40/67 240/400 Varies Ramps 16/44 Yes (f) Autotransformer Any 3 Yes 46 276 40 110 42 Yes (c)(g)
See File: Motor-Start-Char.doc
Motor Starting Characteristics Chart Notes (1) Refer to Factory details. (2) Part Winding Motors must be wound specifically for this service. Some motors may not
accelerate to full speed in the starting mode. See Note (b). (3) Units with two or more contactors have two basic steps (Accelerate & Run) with steps three
and four being for transitions. (4) Starting KW Power as a percent of motor full load power requirement. (a) Also called "A-T-L" or Direct-On-Line. Motor Power Factor taken as 40%. Other values
shown are due to the effects of the controller. (b) Part Winding Parameters vary with the motor. Starting Amps & KVA vary from around
60% to 70%, Starting Torque from around 45% to 50%. The motor can start a fully loaded pump if it has no large torque dip or cusp. See the text discussion on Part Winding Starting for details.
(c) Figures are for tap set at 65% which yields a motor voltage of 65% of line (mains) voltage. (d) The Dual Figures are for Starting and Transition. The transition values are to finish
accelerating a fully loaded pump. Examples include deluge or open systems, re-starting a fully loaded pump after a power failure or interruption, and failure of another pump feeding the same system.
(e) Ignores the momentary transition resistor loads. (f) Varies with pump load and particular Soft Starter used. Values shown are initial and
maximum for a typical fully loaded pump. MCS uses the second (Start) contactor for isolation. Others use only the Bypass contactor.
(g) The 46% Starting Amps & KVA figures include the Autotransformer exciting current.
Motor Starting Characteristics
Parameter Notes to Chart
V. Motor Running TypesConstant Speed Running Full Voltage Running
- Synchronous Speeds (3,600 RPM & etc.)- Slip Frequencies - Running (Rated)
Speeds Motor Lead Wire Running Currents
- Three Lead = Full Motor Current- Six Lead Parallel Run (Part Winding
Start)= 50% of FLC per set
- Six Lead (Wye-Delta Start)= 58% (57.7%) of FLC per set
Motor Running - cont’d
Variable Speed Running Wound Rotor Control
- Changes Motor Secondary Impedance -and-
- Motor Torque Curve Variable Frequency - Variable Speed
Control (VFDs)- Changes Motor Torque and Current
Curves
- Changes Motor Synchronous Speed –and-
- Changes Motor Running (Loaded) Speed
Wound Rotor Speed-Torque Curves
(Reference Source Credit on Next Slide)
Wound Rotor Speed-Torque Curves
- Flipped and Rotated -
Gerhart W. Heumann (G.E.), “Magnetic
Controls of Industrial Motors”, Wiley & Sons.
VFD = Motor Running Only (No Motor Starting Region)
Starting Region
(Reference Only)
Variable Speed ControllersPower Circuit Schematic
. .* Was Optional
Variable Speed Control
VI.Motor Wiring – Motor Lead Configurations (Fourteen)
Three Lead – Three Coil
(Single Voltage) (T1‑T3) Six Lead – Three Coil
– Wye Running (T1‑T3 & T4‑T6)– Delta Running (T1‑T3 & T4‑T6)
Parallel Run (Six Lead - Six Coil)– T1‑T3 and T7‑T8 - or -– Both Sets Labeled T1‑T3
Motor Lead Configurations3 Lead – 3 Coil - Wye Running
Motor Lead Configurations3 Lead – 3 Coil - Delta Running
Motor Lead Configurations6 Lead - 3 Coil - Wye Running
Motor Lead Configurations6 Lead – 3 Coil - Delta Running
6 Lead – 6 Coil - Wye RunningParallel Running
6 Lead – 6 Coil - Delta Running Parallel Running
Motor Wiring – cont’d
Nine Lead (Dual Voltage) (T1‑T9)– Wye Wound– Delta Wound– Suitable for Part Winding Start ?
Twelve Lead (T1‑T12)– Dual Voltage– Single Voltage (Parallel Run)
9 Lead - 6 Coil - Wye RunningSeries Running
9 Lead - 6 Coil - Wye RunningParallel Running
9 Lead - 6 Coil - Delta RunningSeries Running
9 Lead - 6 Coil - Delta RunningParallel Running
12 Lead - 6 Coil - Wye RunningSeries Running
12 Lead - 6 Coil - Wye RunningParallel Running
12 Lead - 6 Coil - Delta RunningSeries Running
12 Lead - 6 Coil - Delta RunningParallel Running
Typical 12 Lead Motor Wiring Diagram
Courtesy of Marathon Electric
Starting Methods -vs- Motor Types
Table M-04 - Motor and Starting Types
Starting Type Motor Type Starting Type Motor Type
Full voltage Standard/Any Primary Reactor Standard/Any
Part Winding Part Winding Primary Resistor Standard/Any
Wye Delta - Closed Delta Run Autotransformer Standard/Any
Wye Delta - Open Delta Run Soft Start (SCR) Standard/Any
Neutral Reactor Wye Running Wound Rotor Wound rotor
Motor Description (a) Starting Method(b)
Run Type Number of Leads Part Winding
Wye (Star) Delta(c)
Neutral Reactor
"Other 5" Figure
Wye Run Three Lead No No No Yes 7-4
Delta Run Three Lead No No No Yes 7-5
Wye Run Six Lead, Single Coil No No Yes Yes 7-6
Delta Run Six Lead, Single Coil No Yes No Yes 7-7
Wye Run Six Lead Parallel Some(d) No No Yes 7-8
Delta Run Six Lead Parallel Some(d) No No Yes 7-9
Wye Run Nine Lead Series No No Yes Yes 7-10
Wye Run Nine Lead Parallel Some(d) No No Yes 7-11
Delta Run Nine Lead Series No No No Yes 7-12
Delta Run Nine Lead Parallel No(e) No No Yes 7-13
Wye Run Twelve Lead Series No No Yes Yes 7-14
Wye Run Twelve Lead Parallel Some(d) No Yes Yes 7-15
Delta Run Twelve Lead Series No Yes No Yes 7-16
Delta Run Twelve Lead Parallel Some(d) Yes No Yes 7-17
Notes: (a) The Motor "Type" (Wye or Delta) is the Running configuration, regardless of how the motor is started. Wound Rotor Motors are not covered in this chart. (b) "Other 5" are: Full voltage (A-T-L), Primary Resistor, Primary Reactor, Soft Start and Autotransformer. (c) Either Open or Closed Transition Wye-Delta (Star-Delta). (d) "Some" = May be used only of the motor is labeled as suitable for Part Winding Starting. (e) The 9 lead "Double Delta" method has unequal currents and is not suitable for standard Part Winding controllers.
Table M-06 -- Motor Suitability
Motor Types -vs- Starting Types
VII. Induction Motors --Installation Considerations Physical
– Location ‑ Ideally Within Site of Controller– Motor Protection: Fire, Security, Other
Hazards– ODP -vs- TEFC– Conduit & Hubs– Environmental
Access – All Sides & Conduit Access Electrical N.E.C. (NFPA 70) ‑ §430 (& §
695)– Conductor Sizing – Incoming & Motor Circuit– Voltage Drops: Start & Run– Cable Impedances and Run Lengths (See NEMA ICS-14)
Motor Installation – cont’d
Environmental Open Drip Proof (ODP) Totally Enclosed Fan Cooled (TEFC) Outdoor Hazardous Locations, Explosion
Proof:– Motor, Controller, Wiring
Other– Salt Air– Wind Blown Sand or Dust– Temperatures– Altitude
Motor Installation – cont’d
Start-up (Commissioning)
Current Measurements Voltage Measurements Estimating Motor Load
– FLA -vs- Voltage– SFA (115%) - Max. Allowed Under
Any Conditions (Temperature, Altitude, Voltage Imbalance) on ANY Phase
Note: NFPA-20 Governs Startup Testing and Procedures