Medium Voltage - Its Use Control and Application by John A Kay, CET

PRELIMINARY COPY
MEDIUM VOLTAGE ITS USE,

CONTROL AND APPLICATION
BY -#R#K#Q####$1###.#D#\/##&#(#7
Copyright 1998,1999
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0.0 1.0 2.0 3.0 3.1 3.2 4.0 4.1 4.2 4.3 4.4 4.5 4.6
Index Abstract What is Medium Voltage Where Medium Voltage is used Why is medium voltage used NEMA Classifications Types of Medium Voltage Motors Squirrel Cage Induction Wound Rotor Multi-Speed Wye-Delta Part-Winding Synchronous 4.6.1 Brush type Synchronous Motors 4.6.2 Brushless Synchronous Motors Starting Medium Voltage Motors Starting The Induction Motor at Full Voltage Wye-Delta Starting Multi-Speed Starting Part Winding Starting Capacitor Assistance Starting Wound Rotor Starting Reduced Voltage Starting Reactor Starting Autotransformer Starting Solid State Soft Starting Torque Requirements Reducing the Starting Voltage and Current of an Induction motor
5.0 6.0 6.1 6.2 6.3 6.4 6.5 7.0 7.1 7.2 7.3 8.0 8.1
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Synchronous Motors and Controls The Synchronous Motor, Brush type The Synchronous Motor, Brushless type
Variable Frequency AC Drive Systems 10.1 Current Source PWM 10.2 VSI Transformer Switching Capacitor Bank Switching Load Break Switches Main Switch Feeder Switch Tie Switch Main-Tie-Main Switch Plugging Re-Generative Braking 0 16.1 16.2 Dynamic Braking of Induction Motors D.C. Injection Braking Dynamic Braking of Synchronous Motors Medium Voltage Controllers versus Switchgear Summary of Medium Voltage Controller Benefits
11.0 12.0 13.0 13.1 13.2 13.3 13.4 14.0 15.0 16.
17.0 18.0
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Copyright 1998, John A. Kay, CET All rights reserved. No part of this book may be used or reproduced in any form or by any means, or stored in a database or retrieval system, without prior written permission of the author. Making copies of any part of this book for any purpose other than your own personal use is a violation of the copyright laws of Canada and the United States. The material contained within is provided without warranty of any kind either expressed or implied. The author and his reviewers have taken the time to validate the technical information contained within. However, the author does not attest to the accuracy of the entire contents of this book and takes no legal responsibility for typographical or technical errors contained within.
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Abstract
The purpose of this document is to provide a brief technical overview of the uses and control of Medium voltage. This document can be used for the development of sales, marketing, and support staff with responsibilities that include the coordination of the quotation and sale of Allen-Bradley Medium voltage Control equipment. A suggested companion document is The Principle Elements of Rockwell Automation/Allen-Bradley Medium voltage Motor Control, by the same author.
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What is medium voltage?
Medium voltage, as defined by NEMA*, is a voltage level between 1000 Volts AC and 13,800 Volts AC. The most common use of medium voltage, in North America, is at levels of 2400 volts, 4160 volts, 4800 volts and 13,800 volts. Voltages of 7200 and 3300 are not widely used in North America. However, in other parts of the world, these levels of voltage are very commonly utilized in commercial and industrial applications. Table 1.0 illustrates the wide variety of typical industrial medium voltage levels and frequencies of some areas of the world. (*NEMA- Nation Electrical Manufacturers Association) Frequencies of 25 Hz, 50 Hz and 60 Hz are typical at medium voltage. The majority of power systems in North America are 60 Hz. However, some older pulp and paper mills that still co-generate power with older equipment, do still operate parts of their facilities at 25 Hz. Also, many countries outside North America, use a 50 Hz power line frequency. Rockwell Automation currently constructs medium voltage control equipment for voltage levels up to 7,200 volts at 50 and 60 Hz applications only. Requirements for 25 Hz control equipment requires specific definition and clarification with the supplier. World Industrial Medium Voltage Electricity Supplies Country Argentina Australia Belgium Bermuda Czechoslovakia Egypt Germany Iraq Israel
Line Freq.
Line Voltage
Country Japan (East) Japan (West) Philippines Romania Singapore South Africa Turkey Venezuela Yugoslavia
Line Freq.
Line Voltage
50 50 50 60 50 50 50 50 50
6800 6600 6000 4160 6000 6600 6000 6600 6300
50 60 60 50 50 50 50 60 50
6600 6600 4160 6000 6600 6600 6300 4160 6600
*Many European states have variations of these base standards. Always check with the local power supplier in the area of the final installation site.
Table 1.0
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Where is Medium voltage used?
Typical applications for Medium voltage include the control of motors larger than 200 horsepower, in industries such as pulp and paper, steel, rubber, cement, mining, petrochemical refining and pipelines, food processing and utilities. Other commercial applications include water and waste water plants, public buildings for air conditioning, pumps, fans and compressors. Medium voltage is also used as the input to transformers that step down the medium voltage potentials to lower distribution voltages. These lower voltages, (240, 360, 480, 575 and 600) are those typically used in motor control centers (MCC) such as the Allen-Bradley 2100 and 2400 product families as well as low voltage drives such as the Allen-Bradley 1300 Products. (Refer to Section 11)
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Typical Industrial Distribution System

Medium Voltage Switchgear
Step Down Transformer
Medium Voltage Control Center
Low Voltage Motor Control Center
Step Down Transformer
Drive Isolation Transformer
Low Voltage Induction Motors
Medium Voltage Drive Medium Voltage Induction Motors
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3.1
Why is medium voltage used?
Generally, a medium voltage motor controller would only be applied on motors larger than 200 HP. In most large facilities, low voltage motor controls are used for motors up to and including 200 HP. On higher horsepower applications, the full load current, at medium voltage, is considerably less than at low voltage, see example 1.0. Example 1.0 500 HP @ 480 Volts = 625 FLA 500 HP @ 4160 Volts = 68 FLA
Therefore, a medium voltage motor and motor control installation could be less expensive than low voltage motors and require smaller fuses, current transformers and power wiring. At 200 HP and above it is usually less expensive to use a medium voltage motor and motor controller than a low voltage solution, providing a medium voltage distribution system exists in the facility.
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NEMA Classifications
The NEMA standards class this type of equipment as class E. This refers to motor starters for synchronous, induction and wound rotor motors rated up to 7200 Volts. NEMA class E2 controllers incorporate high-interrupting capacity fast-acting power fuses. These current-limiting fuses protect the connected equipment, the load cables to the equipment and the controller against the high short-circuit current available from power systems. NEMA class E1 controllers include instantaneous over current relays to signal the contactor or breaker to open on fault current. These relays are in addition to typical motor protection relays. NEMA class E1 controllers may be employed on systems having available short circuit currents less than the interrupting rating of the contactor. All Medium voltage motor control equipment, supplied by AllenBradley, is typically E2 rated.
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4.0
Types of medium voltage motors

Induction Types

Squirrel Cage Wound Rotor Multi-Speed Wye-Delta Part Winding
Synchronous

Brush type Brushless Squirrel cage induction motors
4.1
Squirrel cage induction motors, because of their simplicity, ruggedness and reliability, have practically become the accepted standard for alternating current, all purpose, constant speed motor applications. As a result, various kinds of control equipment and starting methods have been developed for these types of motors. The squirrel cage motor consists of a fixed frame or stator, carrying the stator windings and a rotating member called the rotor. The rotor is made up of steel or iron laminations welded to the motor shaft. The rotor windings consist of many copper or aluminum bars fitted into slots in the rotor member, with each bar connected at each end by a continuous conductive ring. (refer to fig. 4.1a)
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Figure 4.1a
A typical three phase, medium voltage squirrel cage induction motor, has three stator windings wound on the stator frame. These three windings are directly connected to medium voltage through a motor controller. This type of control applies full voltage to the motor by way of a contactor and as such, this method is called Full Voltage Starting, figure 4.1b. (See section 5.0)
Fig 4.1bFull Voltage Starting
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When three phase alternating current is applied to the stator windings, a rotating magnetic field is produced within the stator. This field revolves around the rotor at a speed of (120 X line frequency) number of motor poles. E.g.: With a 60 Hz system frequency, a motor with 2 poles will rotate at a no load speed of 3600 RPM, (120 X 60) 2. These revolving stator fields induce currents through an air gap to the conductive bars on the rotor. These currents will be highest when the rotor is at a standstill and will decrease as the motor comes up to full speed. These magnetic forces, induced on the rotor, will cause the rotor to turn in the direction of the rotating field within the stator windings. The motor will accelerate until a speed is reached corresponding to the required slip* to overcome windage and bearing friction. This speed is referred to as the no load speed. The squirrel cage induction motor can never reach a speed that is synchronous to the line frequency. If the motor was to reach synchronous speed, no current would be induced in the rotor and the motor would produce no torque. (Refer to sec. 6.0) The initial inrush currents, locked rotor currents and the resulting torque values produced are the factors that determine whether the motor can be applied directly across the line or whether the current has to be reduced to get the required performance to match the load requirements and/or utility line voltage flicker or voltage dip specifications.
*Slip The difference between the rotor RPM and the rotating magnetic field of an AC motor
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4.2
Wound rotor motors
This style of induction motor was designed to provide variable speed operation long before the invention of variable frequency drives. The stator of the motor is very similar, and in some cases, identical, to that of a standard medium voltage polyphase squirrel cage induction motor. However, the rotor design differs significantly. The rotor of such a machine consists of a laminated iron core, the outer periphery of which contains slots into which are inserted the form-wound coils. These coils are grouped to form a 3 phase Y (wye) connected winding having the same number of poles as the stator winding. The open ends of the three rotor phases are connected to slip-rings mounted on the shaft. Brushes ride on the conductive slip rings to connect the rotor windings to an external resistor network and shorting contactor arrangement. The rotor slip losses are dissipated in the external resistors versus the internal rotor windings. The starting torque can be raised by increasing the resistance of the rotor circuit. This has the effect of raising the rotor power factor so that the rotor currents are more nearly in phase with the stator flux. At a certain critical resistance, where Rr = Xr, the motor can be made to exert maximum starting torque. If the resistance is either above or below this critical value, the starting torque will be decreased again. A rotor containing enough resistance to give maximum starting torque is not satisfactory, after the motor gets up to speed, as it produces poor running characteristics. An increase of rotor resistance causes the slip to increase for any given value of load. Although the maximum torque which the motor can exert may not be changed, still the speed at which this torque is exerted is lowered, if the rotor resistance is high. If the motor carries its load at a reduced speed, it is running inefficiently, since the rotor copper losses are increased. What is desirable is a rotor of comparatively high resistance for starting but of low resistance for running.
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In contrast with a squirrel cage motor, a wound rotor motor should not be started on full voltage with zero external resistance in the rotor circuit, that is, with slip-rings shorted. Under these conditions, the starting current is usually higher than that of a squirrel cage induction motor of the same rating, and the starting torque is lower. Also, there is a considerable possibility of damage to mechanical elements in the rotor, to any soldered connections of the windings, and to winding insulation, particularly if the motor is started repeatedly in this manner. The wound rotor motor is useful where high starting torque with low starting current is desired. Heavy loads can be started and accelerated slowly and smoothly, without undue line disturbance. It is also used where speed regulation is desired as on fans and centrifugal pumps. Refer to section 6.5 for complete details of how to control of this type of motor.
Fig 4.2a Typical wound rotor control
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4.3
Types of medium voltage multi-speed motors
There are two different types of medium voltage multi-speed starters offer by Rockwell Automation/Allen-Bradley. These are the separate winding and the consequent pole starter. These two types also have specific configurations supplying specific output characteristics. Each type may have either a constant horsepower, constant torque or variable torque. The following sections relate to the design and operating characteristics of multi-speed motors and their associated controllers. Operating characteristics of multi-speed motors Constant Horsepower (a) Horsepower rating constant. (b) Torque rating varies inversely with speed. e.g., machine tool spindles Constant Torque (a) Horsepower rating varies as the speed. (b) Torque rating is constant. e.g. conveyer Variable Torque (a) Horsepower rating varies as the square of the speed. (b) Torque rating varies as the speed. e.g. fan, blower or centrifugal The consequent pole motor has a winding for each of the two speeds. A typical two speed consequent pole motor controller uses 3 contactors. (see Figure 4.3a). A separate winding motor has a separate winding for each speed. The controller would use only 2 contactors. (see Figure 4.3b)
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4.3.1 Consequent pole: Consequent pole motors get their name from the way the windings are reconnected to obtain different speeds. For a typical arrangement for a three phase, four-pole motor, the direction of the current in the various portions of the windings produces north and south poles in alternate winding loops. If one-half of the winding is now reconnected, the direction of the current produces south poles in each winding loop. Therefore, south poles cannot exist alone, so north poles are created between the loops as a consequence. The result is now an eight-pole motor that will run at half the speed of the four-pole arrangement. A two-speed consequent pole motor always has a speed ratio of 2 to 1. A two-speed consequent pole medium voltage controller consists of three, three-pole contactors mechanically and electrically interlocked. For one speed, a three-pole contactor connects the motor across the line. For the other speed, another contactor connects three different leads of the motor across the line. The other contactor is used to tie together the original three leads. See fig. 4.3a In Table 4.1, it can be seen that the torque and the horsepower vary with speed for each type of multi-speed motor. It can be noted that the torque, and therefore the current, of constant or variable torque motors, is never greater than 100%. That is, the current is never greater than it is at full speed. This is not true for constant horsepower motors. Here the torque (and the current) increase at the lower speeds in order to maintain the constant horsepower characteristic. For this reason, the horsepower ratings are lower for constant horsepower starters than for constant or variable torque starters for any given size.
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The values shown in Table 4.1 indicate the horsepower and torque at the full speed of each winding arrangement. They do not indicate the output characteristics as the motor is coming up to the selected speed.
speed full two-thirds half one-third
Constant HP Torque HP 1 1 3/2 1 2 1 3 1
Constant Torque Torque HP 1 1 1 2/3 1 1/2 1 1/3
Variable Torque Torque HP 1 1 2/3 4/9 1/2 1/4 1/3 1/9
Table 4.1 Output characteristics for multi-speed motors.
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Consequent pole summary (a) Single winding, reconnected. (b) Reconnecting creates twice the poles as a consequence. (c) Speed ratios always 2:1
SS
FS T4 T2
T1
T5
T6
T3
SS = Slow Speed FS = Fast Speed S = Shorting Contactor
1LNCONPLTQ.VSD
Constant or Variable Torque
Figure 4.3a
Two Speed Consequent Pole
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4.3.2 Separate Winding Separate winding motors have, as the name implies, a separate winding for each speed. Thus, a two-speed motor has two windings, a three-speed motor has three windings, and so on. These windings are electrically separate and each is capable of delivering rated horsepower at rated speed. The mechanical arrangement of the windings determines the poles per phase, the more poles the slower the rotor speed. Since the windings are independent of each other, so too are the speeds. A two-speed separate winding motor can therefore have widely different speeds such as 3600/600 RPM. The speeds can also be quite close such as 900/720 RPM. Each winding requires a three-pole contactor to connect it across the line. A two-speed starter is constructed similar to a standard reversing starter in the sense that two main contactors are required. The exceptions are that two sets of current transformers and overloads are required, one for each speed. The two contactors are mounted inside one enclosure and are mechanically and electrically interlocked to a single isolation switch. Separate winding summary (a) A separate winding for each speed. (b) Windings are electrically separate. (c) Each is capable of delivering rated HP at rated speed. (d) Independent speeds. (e) Motor types (constant HP, constant or variable torque) has no effect on motor connections.
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FS
SS
FS = Fast speed SS = Slow speed
Figure 4.3b Two Speed Separate Winding
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4.3.3 Motor symbols and starter wiring A)
Separate winding
Separate winding starters consist of an assembly of three-pole contactors, one contactor for each speed. When wiring such a starter to its motor, it is not important to know the output characteristics of the motor. That is, it is immaterial whether the motor is constant horsepower, constant torque, or variable torque. The symbols for a separate winding motor are shown below:
T1 T11 T21
T3
T2
T13
T12
T23
T22
Figure 4.3.3.1 B)
Consequent pole winding
For consequent pole applications, it is important to know whether the motor is constant horsepower, constant torque or variable torque. The standard symbols for these three types are shown below in figures 4.3.3.2, 4.3.3.3 and 4.3.3.4
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Constant Horsepower
T4
T3
T1
T5
T2
T6
Figure 4.3.3.2
Speed LOW HIGH
line 1 T1 T6 Table 4.3.3.1
line 2 T2 T4
line 3 T3 T5
open
tied together T4, T5, T6
T1, T2, T3
Therefore, in the low speed the connections are as in Table 4.3.3.1 in the parallel star. In the high speed, the connections are in the series delta configuration.
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CONSTANT TORQUE
T4 T3
T1
T5
T2
T6
Figure 4.3.3.3 Speed LOW HIGH line 1 T1 T6 Table 4.3.3.2 The low speed connections are in the series delta configuration where as the high speed connection is the parallel star. line 2 T2 T4 line 3 T3 T5 open T4, T5, T6 T1, T2, T3 tied together
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VARIABLE TORQUE
T4
T1 T3 T2 T5 T6
Figure 4.3.3.4
Speed LOW HIGH
line 1 T1 T6 Table 4.3.3.3
line 2 T2 T4
line 3 T3 T5
open T4, T5, T6
tied together T1, T2, T3
In the low speed, terminals 1, 2, and 3 are connected in series star. At high speed, terminals 1, 2, and 3 are tied together and 4, 5, and 6 are connected in parallel star. You will notice that in the figures above that the configurations are all very similar. In fact, the arrangement is the same for the constant torque and the variable torque motors. The same motor leads are connected to the lines for each speed. In addition, leads T1, T2 and T3 are tied together in the high speed. For the constant horsepower motors, it is leads T4, T5 and T6 that are tied together, and this, occurs for the low speed.
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Because the constant and variable torque starters are the same for winding arrangement and also for horsepower ratings, they are grouped together. Physically, the starters look the same, regardless of the type of motor. A two-speed consequent pole starter consists of three contactors, electrically and mechanically interlocked. There are two types of multi-speed starter that Rockwell Automation/Allen-Bradley builds. The Bulletin. 1522 is a NonReversing Medium Voltage Multi-Speed Squirrel Cage Induction Motor Starter. The other type, Bulletin. 1526, is the Reversing Medium Voltage Multi-Speed Squirrel Cage Induction Motor Starter.
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4.4
Wye-Delta motors Star or Wye-Delta starting of squirrel cage motors has always been popular in Europe. This starting method is now employed in North America on large refrigeration compressors and similar compressor applications. The big advantage is that no resistors or transformers are present to produce heat. The disadvantage is that starting torque is low and there are no torque/voltage adjustments. Any squirrel cage motor can be started by this method, provided that it is wound to run with delta connected windings (with full line voltage applied to each winding). There must be 6 wires brought out, both ends of each phase. During start, the motor is connected in Y(wye or star) so that the voltage applied to each winding reduces to one over the square root of three (0.577) of rated voltage. The starting torque will be the square of this value of the full voltage starting torque, or exactly one-third of the normal starting torque. There is no way to alter this value. If the motor were started with the windings in their normal delta configuration, the current taken from each line of the supply system would be root three times the current in each winding of the motor. In the star connection, however, the line current is only one over the root of three, (1/1.73) of what it would have been with the delta connection. The starting current with star connection is therefore exactly one-third of the line current with delta connection. Star-Delta starting therefore, reduces both starting current and torque to one-third of the full voltage value. This is even better than the ratio achieved with transformer starters, because there is no transformer loss. With a typical motor, the starting torque might be 40 % of the rated full load/full speed torque. This is enough to start a lightly loaded machine, but not enough to move any sort of loaded machine.
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With Star-Delta starting, the contactors are connected in the motor legs, not in the supply line. This reduces the current to 57.7% of the line current. The overload relay settings must be selected with this in mind. The basic star-delta circuit is closed transition from START (in star) to RUN (in delta). The added resistors are incorporated in such a way that the circuit is not opened during the transition. If the limited torque is acceptable, star-delta is a very good way to start a motor. Figure 4.4a outlines the three line diagram for the wye-delta starter. Special attention is required to insure the interlocking scheme with the position of the transition resistors.
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1M
2M T1 T2 T3
T6
T4
T5
1A
"1M" & "2M" interlocked to isolation switch "2M" interlocked to "S"
Wye-Delta
W_D.vsd
Figure 4.4a
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4.5
Part Winding Part winding is another method traditionally used by the airconditioning industry, mostly with motors of medium size. The method has little to recommend it except the first cost. In this scheme, two separate (and usually identical) windings are placed on the motor frame. In the running position, both windings are connected to the line (in parallel) and each winding carries half the load. There is a magnetic switch and a set of overload relays for each winding. To start, one of the switches is closed. The inrush current will naturally be lower than if both windings were energized. We might expect the starting current to be cut in half, but in practice, it is more likely to be reduced by only 30 to 35 %. The starting torque, unfortunately, is always low. Typically, it will be only 40 % of the torque that would be supplied at starting by both windings acting together. For this reason, the scheme is applicable only to unloaded machines. The starting current, being concentrated in one winding, constitutes a heavy overload. Properly chosen overload relays are apt to trip out in about 5 seconds. Hence, part-winding starts must be treated as increment type. The timer which brings in the second winding must be set for 1 or 2 seconds, not longer. Part-winding starting must not be tried unless the motor has been wound for the purpose. Even if the motor is wound with part windings, there is likely to be considerable noise and vibration during the starting period. The transition from START to RUN, however, is quite smooth and free of transient disturbances. Because the overload relays are selected for half the total current, CSA requirements limit the branch-circuit fuses to no more than double the total full load current. This is the same as saying 4 times the rated current of each winding.
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Part-winding starting has the virtue of low cost. There are no resistors or transformers, unless a third starting point is wanted. In summary, the part winding motor, the stator windings (each phase) consists of two parallel sections. During starting, half of the windings are connected to the line to provide enough torque to begin acceleration. Then, after a short time, the other parallel windings are also connected to the line. The principal virtue of this type of motor is its low cost. However, torque efficiency is low and there may be torque dips in the torque speed curve. Torque varies significantly depending on the motors rated speed.
Figure 4.5a
Part Winding
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4.6
Synchronous Motors
In the synchronous motor, the basic magnetic field is obtained by direct current excitation rather than through the air-gap from the armature, as is the case with induction motors. Comparatively large air gaps are used, making practicable the manufacture, even in lower horsepower ratings of low speed synchronous motors. In all low speed ratings and in large high speed ratings, synchronous motors are physically smaller and less costly to purchase than squirrel cage induction motors of equivalent horsepower. Where there is a heavy concentration of induction motors, the operating characteristics of the synchronous motor suit it for use in the correction of the induction motors inherently poor power factor. They are also used for exact, constant speed and slow speed loads in many industrial and commercial applications where these precise and constant speeds are important. The synchronous motor is most commonly used over an induction motor on low RPM loads for its higher efficiency, better power factor, constant speed and lower inrush currents. It is made up of a three phase stator winding, a D.C. rotor winding, and a squirrel cage winding. The stator winding is generally identical to that of an induction motor, and the direction of rotation depends on the rotation of the stator flux, so the direction can be changed by reversing two of the stator leads. As the synchronous motor begins to accelerate, the motor, generally, acts as a squirrel cage induction motor. The rotor could be described as the driven device shown below. The rotating magnetic poles set up in the stator windings by the three phase A.C. could be compared to the driver. The driven pulley (rotor) will accelerate and rotate at a speed slightly less than that of the driver (rotating fields within the stator windings) if a load is attached to the driven end. When there is no load attached, the rotor will accelerate to approximately synchronous speed.
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DRIVEN (rotor)
DRIVER (stator) Slippage
Slippage
gears.vsd
Once the motor has reached a speed near synchronous speed, the motor control circuitry will apply the D.C. to the rotor field windings. Once the field is energized, it effectively locks the stator and rotor together as illustrated below. The addition of D.C. to the field effectively creates a chain and sprocket effect. The driver and driven shafts running in perfect synchronous speed to each other.
DRIVEN (Rotor) DRIVER (stator) NO Slippage NO Slippage
DC applied to the rotor field
gears.vsd
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4.6.1 Brush Type Synchronous Motor The rotor contains laminated poles that carry the D.C. field coils that are terminated at the slip rings. It also has a squirrel cage winding which is made up of bars embedded in the pole faces and shorted by end rings. The squirrel cage winding is also known as "damper" or "amortisseur" winding. It is this winding that enables the motor to accelerate to 95% speed were the D.C. supply can be applied to the field windings for synchronizing the motor to the line.
3 A C
N
S
DC from Field Contactor
S N
SYNCMTR.VSD
The field windings are connected through the slip rings to a discharge resistor during start up. The ratio of this resistance to the field winding has a significant effect on the starting torque, the torque at pull-in and, to a lesser degree, to the starting KVA. During the start sequence, the discharge resistor is required to dissipate the high voltages that are induced into the field windings from the stator, and is removed from the circuit when the D.C. field voltage is applied. The synchronous motor can be compared to a transformer, the three phase stator resembling the primary and the field winding acting like a secondary. In addition, the field winding has more turns than the stator so the medium voltage is actually stepped up to a field winding that is insulated for low voltage. This transformer action is where the induced signal is found to determine when the D.C. field can be excited for synchronization. At zero speed, the frequency induced into the field is 60 Hz, at 95% speed the frequency induced is 3 Hz.
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When at approximately 95% speed, the D.C. field, (rotor) is supplied with either 125 VDC or 250 VDC and the discharge resistor is removed from the circuit. The excitation in the field windings creates constant north and south poles in the rotor, which would lock, into the rotating magnetic field of the stator. The slip rings are used to connect the field windings to the discharge resistor and static exciter. 4.6.2 Brushless Synchronous Motors By the 1960s, solid state diodes and thyristors had advanced to where they could carry the current and block the voltages necessary for industrial motor control applications. It was at this time that Brushless Synchronous Motors were developed. The rotor has a three-phase A.C. armature winding. The stationary field winding is on poles on the stator and is connected to a variac and rectifier for the D.C. supply. The generated A.C. current is directly connected along the shaft to a rotating diode wheel, where it is rectified to D.C. before going to the motor field. The magnitude of the field current is adjusted by changing the current to the stationary exciter field.
Discharge Resistor
DC to Exciter Field
Electronic Control and Sensing Component s
3 Phase AC
Field
Armature
Rectifier
Field Application Circuit
Field
Armature
Rotating Portion
Exciter
Rotating Heat Sink Assembly Synchronous Portion
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As with a brush type synchronous motor, the field windings must be shorted with a discharge resistor and the D.C. must be blocked until the rotor is up to near full speed. As with the brush type motor, the ratio of the discharge resistor to the field winding has a significant effect on the starting torque, the torque at pull-in and, to a lesser degree, to the starting KVA. When the motor is near full speed, the D.C. is then applied and the discharge resistor is disconnected from the circuit. All of this control, on a brushless synchronous motor, is found on the rotor of the motor. Conversely, on a brush type synchronous motor all of these controls are located in a separate motor control unit. See section 9 for complete details on synchronous motors and their associated controllers. Synchronous motors are chosen because of one or more advantages they have over induction motors. These advantages are: Generally lower cost when the rating exceeds one HP per RPM
Adaptability to low speed applications <1000 RPM Constant synchronous speed for consistent material processing
Generally lower inrush current Power factor improvement due to operation at 100% PF or up to 80% leading PF.
Higher efficiency
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Some disadvantages encountered with brush type synchronous motors are; More complex motor protection and control system required
The necessity of a DC excitation source and control. Relatively low starting torque per KVA.

Maintenance requirements of commutation system Cannot be used in hazardous locations
Features of the brushless motor; No brushes, no carbon dust, no brush maintenance No commutator/slip rings to resurface Completely automatic field application Automatic resynchronization No sparking. Can be used in hazardous locations No additional static exciter cabinet required
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5.0
Starting Methods for Medium Voltage Motors
There are several factors to be considered when selecting the starting equipment for any electric motor driven load. These include, but are not limited to: 1. 2. The starting torque requirements of the load The motor starting characteristics (torque) that will closely match the load characteristics at full load and speed The source of power and the effects the motor starting current will have on the line or system voltage The effect of the motor starting torque on the driven load
3.
4.
There are three fundamental methods of starting squirrel cage induction motors; full voltage starting, reduced voltage starting and variable frequency starting.
Full voltage starting can be used whenever the driven load can withstand the shock of instantaneously applying full voltage to the motor and where line disturbances can be tolerated. Full voltage starting uses a main contactor to apply the motor stator windings directly across the main system voltage.(ref. Fig. 4.1b) This type of starting method provides the lowest cost, a basic and simple design of controller, resulting in low maintenance and the highest starting torque.
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Reduced voltage starting may be required if full voltage starting creates objectionable line disturbances on the distribution system or where reduction of mechanical stress to gear boxes or belt drive systems is required. It must be noted that when the voltage is reduced from nominal, a decrease in inrush current will occur at a rate of 12% for every 10% decrease in voltage. The starting torque will also decrease at a rate of 20% for every 10% decrease in voltage. This phenomenon also occurs in the opposite manner when the voltage is increased. A common rule of thumb is; "If the load cannot be accelerated to full speed using full voltage and current, it cannot be accelerated to full speed using reduced voltage and current." Variable frequency starting provides infinite speed control of an induction and synchronous motor. The drive converts the line frequency to a D.C. level. It then recreates an output A.C. wave form at variable frequency levels. Drive types and control will be discussed in section 10.
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GENERAL EFFECTS OF VOLTAGE AND FREQUENCY VARIATIONS ON INDUCTION MOTOR CHARACTERISTICS

Efficiency
starting and maximum running torque
Power Factor
1/2 loaded 7-20 point decrease 1 to 2 point decrease full load 3/4 load 1/2 load
sync. speed no change no change
% slip
full load speed 1.5% increase 1% increase (sync. speed slip) 1.5% decrease 5% increase (sync. speed slip) 5% decrease
full load current 11% decrease 7% decrease
starting current 25% increase 10 to 12% increase voltage
temp. rise at full load
max. overload capacity
magnetic noise, no load noticeable increase
full load
3/4 loaded 1/2 to 2 point decrease no change
120%
44% increase 21% increase
30% decrease 17% decrease

1 (voltage)2
5 to 6 C decrease 3 to 4 C decrease
44% increase 21% increase
small increase 1/2 to 1 point increase
Voltage
110%
slight increase
5 to 15 point decrease 3 point decrease
10 to 30 point decrease 4 point decrease
15 to 40 point decrease 5 to 6 point decrease
Variations
function of voltage
(voltage)2
constant no change 5% increase

frequency
(Voltage)2
90%
19% decrease 10% decrease 1 (Freq.)2 11% increase
23% increase no change
11% increase slight decrease
10 to 12% decrease
6 to 7 C increase slight decrease
19% decrease slight decrease
slight decrease slight decrease
2 point decrease slight increase
no change slight increase
1 to 2 point increase slight increase
1 point increase slight increase
105%
Frequency Function of Frequency
5 to 6% decrease
1 frequency
Variations
95%
5% decrease
no change
slight increase
5 to 6 % increase
slight increase
slight increase
slight increase
slight decrease
slight decrease
slight decrease
slight decrease
slight decrease
slight decrease
References: Industrial Electricity, Vol. II; Dawes Electric Motors in Industry; Shoults, Rife, Johnson Electric Machinery and Control; Kosow Electrical Systems and Equipment for Industry: Moore, Elonka John A. Kay
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6.0
Starting an Induction Motor with Full Voltage
Figure 6.0a depicts the behavior of the current required by an 1800 RPM induction motor at various speeds. Two facts stand out: First, the starting current is quite high compared to the running current; and second, the starting current remains fairly constant at this high value as the speed of the machine increases and then drops sharply during the last portion of acceleration to full operating speed.
600
% L o M a o d t o C r u r F r u e l n l t
Motor Current-Speed Curve

500
400
300
200
100
0 0 300 500 900 1200 1400 1700 1800
Rotor Speed (RPM)
Figure 6.0a This means, of course, that the heating effect, to the rotor and the windings, is quite high during acceleration since it is a function of IT. It also means that a motor may be considered to be in the locked rotor condition during nearly all of the accelerating period.
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Figure 6.0b shows a set of torque-speed curves for a typical variable torque load (such as a fan, blower or unloaded centrifugal compressor) and a typical induction motor. At this point, it should be mentioned that both the current-speed and torque-speed curves shown are examples of only one particular class of induction machine. As noted previously, the shape of these curves for any individual motor depends mostly on the configuration, material and placement of the rotor bars. Every load and motor combination will exhibit unique torque speed and current speed curves.
600 Motor Current-Speed Curve Motor Torque-Speed Curve 500 Typical Load Torque Curve
% Motor Current and Torque
400
300
200
100
0 0 300 500 900 1200 1400 1700 1800
Rotor Speed (RPM)
Figure 6.0b
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The example shown in Figure 6.0b depicts the typical characteristics of a Class B induction motor. As the horsepower gets higher, the percentage starting torque will be lower and the sag in the torque-speed curve will become more pronounced. The torque of an induction motor is a function of the square of its induced rotor current, and is therefore approximately the square of its line current. If the starting voltage is reduced to 50%, the motor current will drop to 50% of normal full voltage starting current, but the torque will drop to 25% which comes from (0.5)2 = 0.25 or 25%. Were it not for this fact, reduced voltage starting methods would not create the problems that they do. The inverse is also true. If you increase the voltage the torque will increase in the same proportion. See Fig. 6.0c.
160
140
120
% of Rated Torque
100
80
110 % Voltage
60
100 % Voltage 90 % Voltage 50 % Voltage
40
20
0 0 300 500 900 1200 1400 1700 1800
Rotor Speed (RPM)
Figure 6.0c
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6.1
Wye-Delta Starting
This type of starting method is used for applications where low starting torque is required for loads such as fans and compressors. there are some limitations with this type of starting method. Limitations include a starting characteristic that is not adjustable, as with various reduced voltage methods and the fact that the motor must have a delta stator winding with extra leads for the wye connections, see Fig. 4.4a. Star-Delta starting of squirrel cage motors has always been popular in Europe. It is employed in North America on large refrigeration compressors and similar applications. The biggest advantage versus autotransformer and consequent pole starting is that no resistors or transformers are present to produce heat. The disadvantage is that starting torque is low and there are no adjustments. Any squirrel cage motor can be started by this method, provided that it is wound to run with delta connected windings (with full line voltage applied to each winding). There must be 6 wires brought out, both ends of each phase. During the start cycle, the motor is first connected in a Y (wye or star) so that the voltage applied to each winding reduces to one over the square root of three (0.577) of rated voltage. The starting torque will be the square of the value of the full voltage starting torque, or exactly onethird of the normal starting torque. There is no way to alter this value. If the motor were started with the windings in their normal delta configuration, the current taken from each line of the supply system would be root three times the current in each winding of the motor. In the star or Y connection, however, the line current is only one over the root of three of what it would have been with the delta connection. The starting current with a star connection is therefore exactly one-third of the line current with a delta connection.
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Star-Delta starting therefore, reduces both starting current and torque to one-third of the full voltage value. This is even better than the ratio achieved with transformer starters, because there is no transformer loss. With a typical motor, the starting torque might be 40 % of the rated full load and full speed torque. This is enough to start a lightly loaded machine, but not enough to move any sort of load. With Star-Delta starting, both the contactors and the overload relays are connected in the motor legs, not to the supply line. This reduces the current to 57.7 % of the line current. The overload relays must then be selected with this in mind. The basic star-delta circuit is open transition from START (star) to RUN (delta). It is possible, though, to add resistors in such a way that the circuit is not opened during transition. If the limited torque is acceptable, star-delta is a very good way to start a motor.
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6.2
Multi-Speed Motor Starting
Controllers for multi-speed motors consist of two or more contactors depending on the motor type (refer to section 4.3) The configuration of the contactors and their associated control circuits are dependent on the motor type and method of the starting sequence. If the motor is allowed to start at any desired speed and also allowed to change speed at any time, the control is described as selective start. One run push button is used for each speed and there is only one stop push button. If the control will allow for starting in only one speed before switching to the other speed, this control type is compelling. If the motor is started in low speed and cannot be started in high speed, the control is described as a low speed compelling. But if the control allows only a start at the higher speed before allowing the motor to go to a lower speed, the control is described as a high speed compelling. Shown below are the specific control circuit configurations for various multi-speed motor controllers
MULTI-SPEED CONTROL CIRCUITS

Fast Slow S Stop CR F CR S Fast CR Slow Overlapping F CR S Over-load
Form 'A' Slow speed compelling
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Fast CR1 Stop CR1 Slow TR1 CR1 TR1 S F CR1 S S F TR1 Over-load
CR1 Form 'B' Automatic sequence acceleration
Slow
Fast F
Stop F
S TR
Overload
CR Fast Slow CR F TR S
Form 'C' Deceleration
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TRC Fast Slow CRA Stop F CRC
Overload CRA CRC Fast CRA Slow Overlapping F CRA S TRC
Form 'AC' Slow speed compelling with automatic sequence deceleration
Fast CRB Stop CRB Slow TRB CRB CRB S TRC F TRB Overload
CRC CRC TRB F TRC CRB Form 'BC' Automatic sequence acceleration and deceleration F
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6.3
Part-Winding Starting
This starting method reduces the in rush current to the motor by connecting the sectionalized, parallel stator windings to the line in two or more steps. To accomplish this starting method, the motor must be designed with partwindings. If the motor can be designed for part-winding starting, the resultant starting torque and reduced in rush currents may meet the requirements for specific load and distribution systems at the least possible expense. Refer to section 4.5. Part-winding is another starting method primarily used in the airconditioning industry, mostly with motors of medium size. The method has little to recommend it except the first cost. In this scheme, two separate (and usually identical) windings are placed on the motor frame. In the running position, both windings are connected to the line (in parallel) and each winding carries half the load. There is a contactor and a set of overload relays for each winding. To start, one of the contactors is closed. The inrush current will naturally be lower than if both windings were energized. You might expect the starting current to be cut in half, but in practice it is more likely to be reduced by only 30 to 35 %. The starting torque, unfortunately, is very low. Typically, it will be only 40 % of the torque which would be supplied at starting the motor using both windings acting together. For this reason, the scheme is applicable only to lightly-loaded machines. The starting current, being concentrated in one winding, constitutes a heavy overload. Properly chosen overload relays are apt to trip out in about 5 seconds. Hence part-winding starts must be treated as increment type. The timer which brings in the second winding must be set for 1 or 2 seconds, not longer. The load must accelerate quickly. Part-winding starting must not be tried unless the motor has been wound for the purpose. Even so, there is likely to be considerable noise and vibration during the starting period. The transition from START to RUN, however, is quite smooth and free of transient disturbances.
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Part-winding starting has the virtue of low cost. There are no resistors or transformers, unless a third starting point is wanted. The contactors can be half-size because each one supplies only one half of the motor current.
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6.4
Capacitor Assisted Starting
As was discussed in the previous section, both synchronous and induction motors draw high current during starting. Starting in-rush currents for an induction motor can be six or more times the motor full load current. If the motor is relatively small and/or the distribution system is stiff enough to absorb this brief starting burden, no ill effects will occur to the power system. However, if the starting current is very high and/or if the distribution system is weak , the starting requirements can cause the voltage on the local distribution system to fall so low that other equipment may be affected. This voltage drop, in turn, reduces the motor torque and there may not be enough motor torque to accelerate the load. This high current draw at starting will be reflected back into the local utilities power system. It can cause Voltage Flicker that affects the quality of the power being supplied to other customers. This is the primary reason why most utilities dictate voltage flicker limits during the starting of large loads. One method of reducing this demand on the local distribution system and utility is the application of capacitors to the motor terminals during starting. Capacitor assisted starting can provide an attractive solution to this problem, from the standpoint of initial investment and operating costs. Capacitors can be applied in two methods: 1. 2. As a continuous correction device As a source of reactive power during motor starting.
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Figure 6.4a shows a typical Medium Voltage Motor with capacitors connected for continuous power factor correction.
Figure 6.4a When power factor correction capacitors are connected across the motor terminals they must be sized no larger that the maximum size recommended by the motor manufacturer. The National Electric Code (NEC) also imposes limits on the size of capacitors that can be connected across the motor and switched with the motor controller. If the capacitors are too large and the motor is overhauled by the load, subjected to plug stopping, rapid reversing or jogging damage to the motor can occur. Figure 6.4b shows a typical Medium Voltage Motor and controller where capacitors are used to assist in the reduction of current demand to the distribution system during starting.
C1
C2
Figure 6.4b
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In this case, the contactor C2 is closed prior to closing the main motor starting contactor C1. The capacitor bank is charged to full voltage and C1 is closed. Figure 6.4c indicates graphically the result of applying the capacitor bank at start. With the capacitors placed across the motor terminals, the voltage will rise as the motor accelerates to full speed and the required current will fall to full load requirements. If these capacitors were allowed to remain connected, the voltage will rise in excess of the motors permissible level. Therefore, when capacitors are used to assist in starting only, the controller must have circuitry to sense the system voltage and switch part or all of the capacitors out of the motor circuit if the system voltage rises to an intolerable level. Other methods that can be successfully applied to limit starting burden are reduced voltage controllers using autotransformers, reactors or semi-conductors.
80
Active Current 80 Amps
100
100 Amps Line Current
Reactive Current 60 Amps
Reactive Current 60 Amps
Capacitor
Induction Motor Load
Induction Motor Load
Capaid.vsd
Fig 6.4c
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6.5
Wound Rotor Motor Starting
Section 4.2 outlined the configuration of the wound rotor motor. These types of motors are known for their ability to provide limited speed control and adjustable torque efficiency. The control for these types of motors is more complex than that of a standard induction motor. The principle of the wound rotor motor is that by varying the rotor resistance at various points in the acceleration period can provide a specific torque profile. During starting, a set of external resistors are connected to the rotor through slip rings. As the motor accelerates portions of the external resistors are shorted by contactors, controlled by timing relays, until all external resistance is removed. (Figure 6.5a) In some cases, one portion of resistance is left attached to the rotor if a specific torque profile is needed for the driven load. As stated above, wound rotor motors can be operated at specific speeds. Rotor speed regulation differs from starting duty in two ways. The resistors used, external to the rotor, must be rated for continuous duty and the contactors used to switch in or out specific resistance values, must be rated for continuous duty. If a number of speedregulating points are required, a drum switch is typically used in place of the timing relays used in starting duty.
Figure 6.5a
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The external resistors used are classified by the duty cycle required. Resistors designated as class 135, are typically used for starting duty applications. Resistors used for speed regulation are typically class 151 or higher. Because of the difference in duty cycles, controllers incorporating class 151 and higher class resistors will be significantly larger and more expensive than controllers incorporating only class 135 resistors. The table below outlines various resistor classifications and their associated duty cycles.
Approximate percentage of Full-Load current on first point starting from reset Starting current in percent of full load torque
5 sec. on 75 sec. off

General purpose Intermittent speed regulation duty

Heavy Intermittent speed regulation duty

Extra Heavy Intermittent speed regulation duty
Single phase starting
Three phase starting
Very light Starting duty
General purpose Starting duty
Heavy Starting duty
Continuous speed regulation duty
25 50 70 100 150 200+
15% 30% 40% 55% 85% ---
25% 50% 70% 100% 150% 200%
111 112 113 114 115 116
131 132 133 134 135* 136
141 142 143 144 145 146
151 152 153 154 155 156
161 162 163 164 165 166
171 172 173 174 175 176
91 92 93 94 95 96
* Standard starting duty class provided as standard for motor starting
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7.0
Reduced Voltage Starting
Full voltage starting of motors can produce objectionable voltage flicker. In cases where the supply system does not have the capacity to meet the starting current requirements, these line disturbances can be severe. Starting a motor at reduced voltage can help reduce the amplitude of these disturbances. Reduced voltage starting can be accomplished in several different ways;
Reactor starting; where a starting reactor is placed in series with the motor for a period of time during starting. This method also reduces the voltage, current and torque to the motor according to the reactor tap setting. Autotransformer starting: automatically switching between taps of an autotransformer reduces the voltage, current and torque to the motor according to the tap setting used on the auto transformer. Solid State Starting: a method (soft start, solid state) where a controller ramps the voltage from 0 volts (Voltage Ramp) or from a preset level to the full system voltage over an adjustable ramp time. (current limiting). Units can also be set for specific current level starting as well.
The reduction of starting voltage also reduces the available torque, to the driven load, by the square of the voltage. Table 7.0 illustrates the effects on the torque available from the motor when the voltage is reduced in different starting methods.
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A simple method of determining the motor torque at various reductions of voltage to the motor is: Mta = (Tfv) * (Vap)2 / (Vr)2 Mta - Motor Torque at reduced voltage Tfv - Torque at full voltage (supplied by Motor manufacturer) Vap - Voltage applied to motor (reduced) Vr - Distribution system voltage For Example: A motor applied to a 4160V system with a Locked Rotor Torque of 2000 ft/lbs. is started at a reduced voltage of 80% of the distribution system voltage. Mta = (2000) * (4160 * 0.8)2 / (4160)2 Mta =1280 ft/lbs. of torque will be available or 64% of the torque available at full voltage. This formula also applies to situations where the motor is supplied an over voltage. The relationships still hold true.
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STARTING CHARACTERISTICS
STARTING METHOD Full Voltage Auto 80% 65% 50% Reactor 80% 65% 50% Part winding Voltage to Motor Motor Current + Line Current + Starting Torque + Torque ** Efficiency
100% 80% 65% 50% 80% 65% 50% 100% 100%
600% 80% 65% 50% 80% 65% 50% 70% 55% 33% 0-100%
Wye-Delta Solid State
100% 0-100%
600% 64% * 42% * 25% * 80% 65% 50% high tap 70% low tap 55% 33% 0-100%
100% 64% 42% 25% 64% 42% 25% 50% 50% 33% 0-100%
100% 100% 100% 100% 80% 65% 50% 72% 90% 100% 0-100%
Table 7.0 + Locked Rotor * Does not include magnetizing current of autotransformer ** Torque per KVA
This conflict between torque and current requirements of induction motors is one typical dilemma facing the user of reduced voltage starting equipment. It may be only one of several problems but is the most common and most important.
% Rated Motor Voltage % Starting torque
0 25 50 75 100 Table 7.1
0 6.25 25 56.25 100
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Some local utilities restrict the amplitude of the disturbances, caused by starting large motors and loads at full voltage, on the local distribution systems. If the local utility were to impose a restriction in starting current to 350% of full load current, a reduced starting voltage of 350/600 or 58% would apparently be necessary (a typical squirrel cage induction motor has an inrush current typically 600% of the full load current). We could use an autotransformer at 65%, since it has the nearest standard tap value. This will result in a reduced starting torque of 42% of the motors full voltage torque capacity. Table 7.0 illustrates the effects on torque available when the voltage is reduced in different starting methods.
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7.1
Reactor Starting
It is possible to reduce the motor terminal voltage as required by using a primary reactor. The use of a reactor during starting, results in an exceptionally low starting power factor. Reactors must be carefully designed and applied since any saturation in the reactor will produce in-rush currents close to those seen during full voltage starting. Reactor starting has one major advantage; the voltage to the motor is a function of the current taken from the line. It can therefore be assumed that during acceleration the motor voltage will rise as the line current drops. This relationship results in greater accelerating energy at higher speeds and less severe disturbances during the transition to full voltage.
1LNReact.VSD
Figure 7.1
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7.2
Autotransformer Starting
In general, the most widely used method of reduced voltage starting for squirrel cage induction motors is the autotransformer. Reduced voltage autotransformer starting is preferred over primary reactor starting when the starting currents must be held to a minimum and maximum starting torque per line amp is required. (see Table 7.0) There are two very autotransformer starter. distinctive characteristics of an
1) The motor terminal voltage is not a function of load current and remains constant during the acceleration time. There is some regulation within the autotransformer, however, this is negligible. As well, from the standpoint of overall power factors, the magnetizing currents are also negligible. 2) Due to the turns ratio advantages, the ratio of primary line current to torque is the same for autotransformer starting as for full voltage starting. The primary line current is less than the secondary motor currents. Since the turns ratio also represents the voltage ratio, the starting current is reduced by the square of the turns ratio It should be noted however that the motor current and line current are not equal as they are with a primary reactor. A three coil autotransformer is connected in a wye configuration and connected to the motor in such a way as to supply reduced voltage to the motor when the line voltage is applied to the autotransformer. Several sets of taps are usually available to the user to provide different values of reduced voltage (NEMA standards are 80%, 65% and 50% of the full line voltage).
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For example, take a motor with a full voltage starting torque at 120% and a full voltage starting current of 600%. If the power company limitation is 400% current at start, motor current need not be limited to 400%, but only the line current. Since the transformers will have a step down ratio, the motor current can be larger for the given line current. In the example noted, with the line current limited to 400%, one can apply 80% voltage to this motor, have 80% motor current, and still have only 0.8 x 80% or 64% line current due to the 1/0.8 turnsratio for the transformers. The advantage is that the starting torque is now 80% x 80% of 120%, or 77% instead of the 51% obtained in the reactor scheme. In the preceding example, this might easily have furnished sufficient accelerating energy to start the load. Two types of autotransformer connections or control schemes are in common use today. One is designated closed-circuit transition or "Korndorfer-connection," named after its inventor, and the other open-circuit transition. The Allen-Bradley Company has adopted the closed circuit transition autotransformer connection even though it is more expensive to manufacture than starters utilizing the open-circuit connection. Undesirable transient line surges of current are eliminated with this system since the motor is never disconnected from the power supply or transformer. Figure 7.2a is a typical diagram of the closed-circuit transition starter. The taps, of the autotransformer, are permanently connected to the motor. Three contactors are used.
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1LNAUTOTX.VSD
Figure 7.2a
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7.3
Solid State Reduced Voltage Starting
The use of solid state reduced voltage starting can provide a smooth stepless method of accelerating and smoothly decelerating a squirrel cage induction motor. This type of starting method, when properly applied, can provide an efficient and reliable means of smoothly starting and stopping a motor and load. The use of solid state reduced voltage starting will perform, in most cases, more efficiently than fluid couplings, eddy current drives, wound rotor motors and controllers and clutches. The stepless ramped acceleration and deceleration capabilities of this type of starter will reduce the inrush currents to the motor, eliminating transitional shocks to the load and reducing voltage flicker on the distribution system. Solid state starters have become more prevalent in the industrial market place primarily due to the availability of higher voltage silicon switches called thyristors, more commonly known as SCRs. The SCR blocks reverse current and only permits current flow in the forward direction when a signal is applied to the gate of the device. One the SCR is turned on by the gate signal, it stays on until the current through the device drops to zero or changes polarity, (zero crossing). In the case of the a solid state motor controller, two SCRs are connected back to back to control a single phase of AC current. Therefore, for three phase applications, a minimum of three pairs of SCRs are required. Where the system voltage exceed the capabilities of the SCR, multiple SCRs in series parallel can be used. The voltage is varied to the motor by gating the SCRs at varying times within the half cycle. The later in the half cycle the SCR is gated the lower the voltage output. Conversely, the earlier in the cycle the SCR is gated the higher the output voltage. When the SCR is gated on during the entire half cycle, the output voltage is almost equal to the line voltage except for a small voltage drop across each device. Refer to Figure 7.3a
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0% Voltage
25% Voltage
50% Voltage
100% Voltage
Figure 7.3a It is because of this voltage drop, (energy loss), that it is becomes more economical to bypass the SCRs after the motor is up to speed. The Solid Starter controller is NOT used for continuous speed adjustment. These controllers are used strictly for smoothly starting and stopping of a motor. If the solid state controller is used for ramp stopping duty, the SCRs must be fired full on before the bypass contactor is opened. The SCRs are then phased back to reduce the voltage to the motor thus allowing the motor to smoothly come to a halt, In the case of medium voltage solid state starters, the SCRs are operating at true medium voltage levels. As such, the device must be physically isolated from the low voltage controls. The gate firing signals are transmitted from the main microprocessor control module, to a separate gate firing printed circuit board by way of optical signal carried through fiber optics cables. This method of triggering the SCRs to conduct provides the utmost in isolation for personnel safety. The main control module allows for specific firing characteristics. The Rockwell Automation/Allen-Bradley SMC provides the following starting and stopping features.
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Soft Start with Kickstart This is the general method of soft starting. The initial torque value is set between 5-90 % of locked rotor torque. The motor voltage is increased steplessly during the acceleration ramp period which is adjustable from 2 to 30 seconds. A kickstart torque pulse is dip switch selectable. This provides a current pulse of 500% of full load current and is adjustable from 0.4 to 2 seconds. This feature allows the motor to develop additional torque at start. Current Limit Start This starting mode is used when it is necessary to limit the maximum starting current. This can be adjusted from 50 to 500 % of full load amperes. The current limit starting time is set by the user. Full Voltage Start This mode is used in applications requiring across-the-line starting. The ramp time is less than 1/4 second. The SCRs are phased from their full off position to full on in this 250 msec. time frame. Soft Stop Option This function can be used in applications that require an extended ramp to rest. The voltage ramp down time can be set from 2 to 60 seconds. The starting and stopping times are independently adjusted. The load will stop when the voltage drops to a point where the load torque is greater than the motor torque.
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Pump Control Option This function is used to reduce surges in a pumping system during the starting and stopping of centrifugal pumps. The Allen-Bradley MV SMC PLUS Controller controls the speed of the motor during starting and stopping without feedback devices.
SMB Smart Motor Braking Option This function provides motor braking for applications which require the motor to stop quickly. It is a microcomputer based braking system which applies three phase braking current to a standard squirrel cage induction motor. The strength of the braking current is adjustable from 150 % to 400 % of full load current.
Main Contactor
Bypass Contactor
Control Logic
1LNSMC.VSD
Figure 7.3b Typical Solid State Motor Controller c/w bypass
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8.0
Torque Requirements
When the rotor is at a standstill, the rotating flux caused by the stator induces voltages in the rotor bars and since the rotor bars are short circuited, significant currents are induced to flow. The rotor currents react with the air gap flux to generate forces that try to turn the rotor and that try to reduce the induced effects in the rotor. The rotor begins to turn in the same direction as the rotating flux fields produced by the stator.
Direction of rotation of armature with respect to field
Direction of rotation of field structure S
N
Induced armature currents
Actual rotation of armature
S N
Torque.vsd
Figure 8.0a It is important to reiterate that when the voltage is reduced for starting a motor, so are the current and torque values. It should be apparent that a motor that will not start a load at full voltage, will not start that same load under reduced voltage conditions.
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8.1
Reducing the starting voltage and current of an induction motor
As outlined earlier, when the voltage is reduced from nominal (100%), a decrease in inrush current will occur at a rate of 12% for every 10% reduction in voltage while starting torque will be decreased at a rate of 20% for the same reduction of voltage. Refer to Table 7.0. and table 8.1 below
Table 8.1 % Rated Motor Voltage % Starting torque
0% 25% 50% 65% 75% 80% 100%
0.00% 6.25% 25.00% 42.00% 56.25% 64.00% 100%
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9.0
Synchronous Motors and Controls Synchronous motors are used on continuous load applications (such as motor generators, compressors, mills etc.) where there is a need to improve the power factor of a plant distribution system and/or where constant speed is required. Synchronous motors are usually larger than 40 horsepower and, unlike an induction motor, they have an additional rotor field winding which requires DC excitation. Therefore, a motor controller for a synchronous motor not only connects the AC Line voltage to the motor stator but must also apply a DC excitation voltage to the rotor field winding. It must also protect the rotor field and stator windings from overload conditions during the starting cycle, and while operating at synchronous and at sub-synchronous speed.
An application where constant speeds are required are in log chippers for the pulp and paper industry. Constant speed of the chipper drum will result in consistent size wood chips. Consistent sized chips will allow the consistent processing of the raw chip into stock product. There are two types of synchronous motors, brush and brushless, (see section 4.0). The brush type employs an external DC excitation control circuit which is connected to the rotor mounted field winding through brushes and slip rings (Figure 9.0b). The brushless type employs an internal rotor mounted DC excitation control circuit. The more common is the brush type on existing motors. However, newer motor designs incorporate a brushless type of excitation as standard.
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9.1
The Synchronous Motor Controllers, Brush Type
The synchronous motor has a stator winding that is identical to that found in a squirrel cage induction motor. The rotor, with a field winding wound around field poles, is energized from a DC source, (Static Exciter), to produce alternating north and south poles, that mate with opposite magnetic polarity poles in the rotating field set up in the stator. During the start sequence, the motor also acts similar to a standard squirrel cage induction motor. While the motor is accelerating, the rotor winding is connected to an external discharge resistor. The purpose of this resistor is two fold. 1. To provide a load path for the currents induced into the rotor from the rotating stator windings 2. Determines the starting torque profile of the motor during the acceleration phase. (Refer to figure 9.0b) 3. Determines the pull-in torque profile of the motor. 4. Effects the starting KVA, to some degree.
When the rotor reaches a speed that is approximately 95% of synchronous speed, the DC supply is connected to the rotor winding (amortisseur).
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3 A C
N
S
DC from Static Exciter
S N
SYNCMTR.VSD
Figure 9.0a The synchronous motor, therefore, is supplied with two sources of energy, 3 phase AC to the stator and DC to the rotor field. Maximum torque generation only occurs when the rotor field winding is supplied with DC power and the rotor is rotating in synchronism with the rotating field in the stator.
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Rectifier Transformer
Discharge Resistor
Regulated D.C. Exciter
MS
Field Contactor
1LINESYN.VSD
Figure 9.0b
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Rockwell Automation/Allen-Bradley provides three exciters types. A static exciter can best be describes as a D.C. power supply. The three types are; single phase style "A", three phase style "A", and three phase style "B". Each type of static has a step down transformer, a full wave bridge rectifier and a means of controlling the D.C. output. On any of the three the D.C. can range from a few amps to several hundred amps. The style "B" three phase static exciter uses a full wave diode bridge rectifier and a step down transformer to reduce the supply voltage, normally medium voltage. The bridge rectifier is a full wave three phase diode bridge sized to the motor field current Line voltage is obtained after the main contactor, since the isolating switch is a non-load break device. The step down transformer has taps to provide for DC voltage adjustment down to about 70% of the nominal DC voltage rating. . This type of D.C. supply provides manual voltage regulation only. A specific voltage is determined based on required motor current and field resistance to set the correct transformer tap. This way the voltage is set and the current varies with the load. This system is least desirable since load changes, and field resistance changes will affect the power factor. The style "A" static exciter is supplied by a single or three phase source. The single phase circuit is connected to the load side of the main contactor, which is fed by way of a rectifier transformer, to a half controlled SCR bridge, which provides full wave rectification. The three phase, style A static exciter rectifier transformer, is fed from the load side of the contactor. The three phase half controlled bridge rectifier provides full wave rectification. The SCR's are fired by a control circuit which takes a feedback signal from a D.C. current shunt and a set point from the field current adjust potentiometer located on the starter door. The three phase style A static exciter can provide current, voltage, or power factor regulation. The standard control provides current regulation. The current is referenced from the DC current shunt that
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is in series with the motor field windings. The 0-5OmV signal provides a reference to the regulator circuit which will indicate to the circuit how to fire the SCR'S. Current regulation will provide a constant current by varying the voltage supplied. This constant current will overcome the effects of motor winding heating and small load variations to provide stable motor control. Although available on the current style A exciter, voltage regulation is not usually used since it does not provide a very stable power factor. The three phase style "B" system provides voltage regulation. Power factor regulation requires a 0-20 mA signal be fed into the regulation system. This is the ideal form of regulation since it will provide a stable power factor, and overcome motor winding heating and load changes. On synchronous motors the power factor, D.C. field excitation current, and AC stator line current are related. This is reflected in a set of V curves. Under full load with rated excitation the stator current should be at 100%. if the field is over excited the stator current will go up, if under excited the stator current will also go up.
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9.2
Brushless Synchronous Motor Controllers
The rotor, of a brushless synchronous motor, has a three-phase A.C. armature winding identical to that of a brush type motor. The stationary field winding is on poles on the stator and is connected to a variac and rectifier for the D.C. supply. The generated A.C. current is directly connected along the shaft to a rotating diode wheel, where it is rectified to D.C. before going to the motor field. The magnitude of the field current is adjusted by changing the current to the stationary exciter field. This stationary exciter current is typically in the range of 1-10 amps only. As with a brush type synchronous motor, the field windings must be shorted with a discharge resistor and the D.C. must be blocked until the rotor is up to near full speed. When the motor is near full speed, the D.C. is then applied and the discharge resistor is disconnected from the circuit. All of this control, on a brushless synchronous motor, is found on the rotor of the motor. Conversely, on a brush type synchronous motor all of these controls are located in a separate motor control unit.
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Control Circuit Transformer
Powerstat
20 Amp. Full Wave Bridge Rectifieir D.C. Relay
MS
1LINBSYN.VSD
Discharge Resistor, field contactor, and static exciter mounted on rotor shaft
Fig 9.2a
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10.0 Medium Voltage Variable Frequency Motor Drive Systems Traditionally variable voltage drives have been used primarily with DC motors. However, with the increased need for variable speed control of AC motors throughout industry, the use of AC variable frequency drive systems has overtaken the use of DC drives. There are primarily two basic types of AC motor drives; current source and voltage source. The primary operating difference between the two is the speed response rate (rads/sec.). In the case of a current source (fig. 10a), all of the current required by the inverter is pulled through a large link reactor that places a high impedance between the rectifier and inverter. In a voltage source (fig. 10b), instantaneous current is supplied by a large capacitor connected between the rectifier and inverter sections. With little impedance, the capacitor will provide instantaneous currents when called upon by the inverter. Thus, very quick changes in the inverter outputs can be realized. These very quick speed changes, in the order of >30 rads/sec, can be very important for system drive applications such as rolling mills, paper processing and test stands. Where rapid speed changes are not necessary, the current source drive provides an inexpensive and less complex alternative. Typical applications for current source drives include fans, pumps and blowers. These types of loads traditionally do not require quick speed changes, but rather smooth speed changes and tight control.
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Rectifier
DC Link Inductor Inverter SCRs
GTOs
Isolation Switch
Input Contactor
Motor
Power Fuses
Transformer Motor Filter Capacitors SCRs
OPTIONAL
GTOs
Fig. 10.0a Typical Medium Voltage Current Source Inverter, A.C. Drive
In both the current source and voltage source drive, the main system voltage is rectified to DC. This DC supply is fed to a three phase inverter that reconstructs the AC wave form at frequencies typically between 5 to 70 Hz. In some cases drives are available with inverters that output maximum AC frequencies as high as 200 Hz for medium voltage drives. Low voltage drives use much higher switching frequencies (>2K Hz). To provide the conversion of power from one type to another, (AC-DC-AC), a variety of high current semiconductor switching devices are used. The most common devices used for medium voltage drives are silicon controlled rectifiers or thyristors (SCR) and gate turn off thyristors (GTO). The thyristor is an established high power switching device that can be easily turned ON but is very difficult to turn OFF. The GTO has similar attributes as the thyristor with the added ability to turn OFF using a gate control signal. In low voltage drives (600V), the most common semiconductor used is the IGBT.
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The rectifier portion of the drive converts the three phase fixed AC voltage line supply into variable DC voltage. This is accomplished by switching the appropriate power semiconductors at intervals of 120 degrees on the positive portions of the AC sine wave. The opposing semiconductors are switched during the negative portion of the wave form. In the current source drive, the inverter converts the DC link current back into variable frequency AC to the motor. Appropriate switching of the semiconductors transfer the DC link current to the AC output terminals. The wave shape of the output current depends on the time of operation of each semiconductors. The actual output consists of variable duty width square wave pulses. A motor filter capacitor along with the inductive components of the motor load cables and stator windings filters the output wave form to be near sinusoidal.
DRIVE1.VSD
Figure 10.0b Typical Medium Voltage, Voltage Source Inverter, VSI
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11.0 Transformer Switching Medium voltage controls are primarily used for motor control and protection, however, they can be safely applied to control large distribution or isolation transformers. These styles of transformers usually range in sizes between 150 KVA and 10000 KVA at voltages between 2300 to 7200 Volts. Large transformers must be adequately protected in the following basic areas: 1. 2. 3. Overload protection Winding faults (secondary and primary) Single phasing
Other styles and types of protection may also be specified. These could include, but are not limited to, undervoltage, ground fault, internal pressure fault and differential faults. In medium voltage controllers, current limiting fuses are used to protect the transformer primary windings and the cable running from the controller to the transformer, from faults. The power fuses used in this application are typically E rated having the ability to clear high level fault currents very quickly. They are also capable of carrying high in-rush (transformer magnetizing) currents in excess of 9 to 14 times rated full load current without opening or sustaining damage. These in-rush currents are typically only seen for approximately 0.1 seconds (100 milliseconds) during energization of the transformer. These types of power fuses should not be considered overload devices and as such should be coordinated with an appropriate overload relay to provide proper overload protection of the fuse.
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12.0 Capacitor Bank Switching
In section 6.4, we discussed the use of capacitors to correct power factor and their use to assist in starting large loads on weak power systems. Vacuum contactors can be safely applied to switch large banks of capacitors. The main concern is the time it takes for the contacts to close. Because there is inherently some inductance in the circuit, either due to purposely installed air core inductors or inherent circuit inductance, a resonant series circuit is formed. When the contacts of the vacuum bottle begin to close, the inrush currents are proportional to the RMS voltage across the contacts of the vacuum bottle and the circuit impedance at the point the arc begins. This inrush current can easily be ten times the running current. Increasing the inductance of the circuit helps reduce the inrush currents and resonant frequency. Allen-Bradley includes air core reactors in all power factor correction capacitor bank switching configurations to limit the initial in-rush current.
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13.0 Load Break Switches In areas where repeated energization and de-energization, of a load, is not required, as with a motor controller, a load break switch may be a more appropriate switching means. A load break switch is a mechanically operated switch capable of making or breaking, and operating continuously at its rated currents. Typical sizes include 400, 600 and 1200A. Unlike the non-load break switch within a standard motor controller, the load break switch is not mechanically interlocked to any other device with the exception of the safety door interlocks. Load break switches use a stored energy system to provide a means of a quick make and quick break cycle. Load break switches should not be used for motor loads due to safety considerations. The following sections describe some typical load break switch configurations.
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13.1 Main Switches A load break switch used as a Main Switch is used to switch power to a group of devices operating at the same potential voltage. Figure 13.1a illustrates a typical example.
O p tio n a l fu s in g
Figure 13.1a
MAIN
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13.2 Feeder Load break Switches A load break, used as a feeder, obtains its power from a common system bus. It is sized to switch only a single load device, typically a step down transformer. Figure 13.2a illustrates a typical feeder load break configuration.
O p tio n a l fu s in g
Figure 13.2a
FEEDER
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13.3 Tie Load break Switches Load break switches can also be used to tie two distribution busses together. This type of configuration is typically used in applications where the user wants the ability to feed essential equipment in the event of a main power feed failure. Figure 13.3a illustrates a typical configuration. Normally the load break switch shown would be locked in the open position. If either feed A or B was lost, all essential loads could be operated from on main feed.
Feed A
Optional fusing
K
Feed B
* * K
Essential load Kirk-Key Interlocked TIE
Figure 13.3a
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13.4 Main-Tie-Main Load break Switch Combination The use of main load break switches local to the distribution system, in combination with a tie load break switch, allows for local section of main feeds and tie configurations. Figure 13.4a shows a typical main-tie-main configuration. With this type of arrangement all three switches are key interlocked to prevent closure of all three switches simultaneously. This arrangement would allow for a power source to essential loads from either Feed A or Feed B if one of the two sources failed.
Feed A
K
Feed B
Optional fusing
* * K Essential Load Kirk-Key Interlocked MAIN-TIE-MAIN
Figure 13.4a
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14.0 Plugging Plugging is used to bring a rotating motor to an abrupt stop by briefly reversing any two of the three stator connections. The plugging torque varies between the limits of one half to full motor starting torque, the exact amount depending on the resistance of the rotor windings. The higher the resistance the higher the ratio of plugging torque to starting torque. During the plugging cycle, the motor current is slightly higher than the starting current. Any reversing starter designed for plugging control can be used for plugging a motor. Plugging control is usually employed to bring a motor to a stop automatically. A speed-detecting switch is typically attached directly to the motor shaft. The contacts of this switch close as long as the motor is rotating. When the motor rotor is near or at a standstill the contacts of the switch are open. This switch is used signal the removal the plugging operation. The act of plugging a motor is extremely torturous on the motor. The energy transmitted from the load to the motor is NOT fed back into the line, but rather it is dissipated as heat within the motor as losses. The driven load and its associated couplings or gearboxes must be capable of the high torsion shock that plug stopping a motor can place on them.
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15.0 Re-generative Braking An induction motor is capable of developing braking torque which opposes the load torque. If a motor is driven by the load in the same direction as the rotation, the motor speed can rise above synchronous speed. The motor then acts as an induction generator, taking magnetizing current from the line and absorbing mechanical power through the shaft. Effectively, power is fed back into the power system.
As the slip becomes negative (super-synchronous speed), the motor begins to develop a braking torque. The maximum value of this torque is slightly higher than the motor torque at rated speed. This torque value is dependent on the stator resistance. This regenerative braking torque is only possible as long as the main A.C. supply remains connected to the stator. As well, if the load torque exceeds the regenerative torque, the load will become unstable and run away. This mode of braking is used on loads where the motor is restraining an overhead or hanging load. In both cases, gravity assists in the regenerative action.
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16.0 Dynamic Braking of Induction Motors 16.1 D.C. Injection Braking If the stator of a squirrel cage induction motor is excited with D.C., a D.C. flux is set up in the motor that is stationary. As the motor is driven by the load inertia, the rotor conductors (bars) intersect this stationary D.C. flux. An EMF is generated in the rotor bars causing current to flow in those bars. This current, in conjunction with the D.C. flux develops a torque that is opposite to the torque driving the load. Any two of the three-stator windings can be connected to the D.C. supply. The third winding does not require a connection and is left idle. The amount of braking torque varies with the amount of D.C. injected. Higher average braking torque can be realized over the speed range than with plug stopping. The braking torque forces increase to their highest value as the rotor speed drops, but it decreases to a minimum when the rotor approaches standstill. An important aspect of this style of braking is that the motor will not be forced to rotate in the opposite direction as was possible with plugging.
High Voltage D.C. Contactor
Mechanical Interlock
A.C. From a separate Source
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16.2 Dynamic Braking of Synchronous Motors When a synchronous motor is set up for dynamic braking, resistors are connected to the stator windings after the A.C. is removed. With the field still energized, significant braking torque can be realized. In fact, the motor and the drive system must be capable of withstanding the extreme torque transients related to this style of motor braking. This type of braking method is very common in the rubber industry. Banbury and rolling mills use this style of braking to provide immediate personnel protection in the event that an operator becomes entangled in the operating mechanism.
A.C. from a separate source
Discharge Resistor
Regulated D.C. Exciter
MS
dybksyn.vsd
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17.0 Motor Controllers versus Switchgear Medium Voltage Motor Controllers use a combination of a high interrupting capacity current limiting power fuse for short circuit protection, an electrically held contractor to make and break the load currents and an overload relay to protect both. Because of this simple design, repeated operations can be accomplished efficiently with little maintenance needed on the equipment. The vacuum contactors used presently, can perform up to a million operations before replacement should be required. Switchgear on the other hand, consists of only a high interrupting capacity, mechanically latched circuit breaker. The circuit breaker can be of similar design to a contactor except it is designed to withstand and interrupt very high levels of fault current. Also, the circuit breaker is always latched closed by a mechanical, trip-free linkage and is tripped open magnetically or mechanically. Since the breaker is latched closed, it is essential that a reliable source of tripping energy is available to trip the coils. Therefore, the trip coils of a circuit breaker are typically energized from a DC supply with battery backup. The circuit breaker is made up of many mechanical linkages and trip mechanisms that require specific routine maintenance. Also, the breaker is only capable of a few hundred operations before contact or vacuum bottle replacement is required. The inherent high interrupting capability of the circuit breaker produces very high levels of chop currents. These currents and the related transient recovery voltage can be extremely high in comparison to the contactors used for motor control applications. The TRVs can be very harmful to cable and motor insulation if not properly suppressed.
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18.0 Summary of Medium Voltage Controller Benefits
1. Long operating life - medium voltage contactors are designed for many operations. Most 400 A vacuum contactors have an electrical life rating of 1,000,000 operations, and a mechanical rating of 2,500,000 operations. 2. Limited Thermal and Mechanical Stress
A typical breaker takes 3 to 5 cycles to open. Therefore, during a fault condition, all downstream equipment is subjected to tremendous mechanical and thermal stresses for this time period. Current limiting fuses in a controller will clear a fault in one-half cycle or less. The magnitude of the let through short circuit fault current is reduced to almost one third. Since stresses are proportional to the square of the let-through fault current, they are reduced to almost oneninth magnitude and the duration is reduced to almost one-tenth versus a circuit breaker. 3. Station Batteries Not Required
Medium voltage contactors are typically held closed electrically. An internal control power transformer provides all power. No external AC or DC power source is required. 4. Simpler, Reliable and Less Expensive A standard controller: (a) (b) (c) (d) is lighter in weight is simpler in construction has less linkages, bearings and springs is designed for frequent switching
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FEEDBACK FORM
To aid the author in continuously improving the contents and quality of this book, please use this form to relay errors of omission or inconsistencies back to the author.
Section/page:
Name: _________________________________________________ Address:________________________________________________ Phone #: _____ - _____ - ______ FAX #: _____ - _____ - _______ Contact author @ 519-740-4734, FAX 519-740-9871 Thank You!
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Medium Voltage - Its Use Control and Application by John A Kay, CET

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PRELIMINARY COPY

MEDIUM VOLTAGE ITS USE,

rev. 0.9I back up master on LAN

9.0 9.1 9.2 10.0

What is medium voltage?

6800 6600 6000 4160 6000 6600 6000 6600 6300

6600 6600 4160 6000 6600 6600 6300 4160 6600

Where is Medium voltage used?

3.doc Rev 9/28/97

Typical Industrial Distribution System

Step Down Transformer

Medium Voltage Control Center

Low Voltage Motor Control Center

Step Down Transformer

Drive Isolation Transformer

Low Voltage Induction Motors

Medium Voltage Drive Medium Voltage Induction Motors

Why is medium voltage used?

Types of medium voltage motors

Squirrel Cage Wound Rotor Multi-Speed Wye-Delta Part Winding

Brush type Brushless Squirrel cage induction motors

Fig 4.1bFull Voltage Starting

Wound rotor motors

Fig 4.2a Typical wound rotor control

Types of medium voltage multi-speed motors

speed full two-thirds half one-third

Constant HP Torque HP 1 1 3/2 1 2 1 3 1

Constant Torque Torque HP 1 1 1 2/3 1 1/2 1 1/3

Variable Torque Torque HP 1 1 2/3 4/9 1/2 1/4 1/3 1/9

Table 4.1 Output characteristics for multi-speed motors.

SS = Slow Speed FS = Fast Speed S = Shorting Contactor

Constant or Variable Torque

Two Speed Consequent Pole

FS = Fast speed SS = Slow speed

Figure 4.3b Two Speed Separate Winding

4.3.3 Motor symbols and starter wiring A)

Consequent pole winding

Speed LOW HIGH

line 1 T1 T6 Table 4.3.3.1

tied together T4, T5, T6

Speed LOW HIGH

line 1 T1 T6 Table 4.3.3.3

open T4, T5, T6

tied together T1, T2, T3

"1M" & "2M" interlocked to isolation switch "2M" interlocked to "S"

DRIVER (stator) Slippage

DRIVEN (Rotor) DRIVER (stator) NO Slippage NO Slippage

DC applied to the rotor field

DC from Field Contactor

Electronic Control and Sensing Component s

Field Application Circuit

Maintenance requirements of commutation system Cannot be used in hazardous locations

Starting Methods for Medium Voltage Motors

GENERAL EFFECTS OF VOLTAGE AND FREQUENCY VARIATIONS ON INDUCTION MOTOR CHARACTERISTICS

sync. speed no change no change

full load current 11% decrease 7% decrease

starting current 25% increase 10 to 12% increase voltage

temp. rise at full load

max. overload capacity

magnetic noise, no load noticeable increase

3/4 loaded 1/2 to 2 point decrease no change

44% increase 21% increase

30% decrease 17% decrease