Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 1 Motor Starting Technologies Jack Smith – SYD Joe Pickell - RA

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 1

Motor Starting Technologies

Jack Smith – SYDJoe Pickell - RA

2 Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Objective

• Review the basic motor starting technologies:– Across the line– Reduced voltage– Variable frequency

• Understand the selection criteria for each technology• Review application considerations for each starting technology

– Relative cost– Effects on available torque– Maintenance issues– Reliability


Across The Line Starters

• Electromechanical or Solid State switch that closes the motor power circuit.– Motor is either on or off

• Various design standards exist for contactors– NEMA– IEC – Definite Purpose

• Characteristics– Motor has full voltage available as soon as power circuit closes

• Pulls an inrush current 5-7X Normal running current• Motor can produce full torque immediately


Across the Line Starter - NEMA

Advantages•Available up to NEMA size 9, 1600HP @480VAC, 2250A•Simple design, few moving parts, reliable•Proven durability•Versions tested for various applications•Field serviceable•UL and CSA approved•Allen Bradley tested to 10 million operations

Limitations•Not touch safe•Physically large•Panel must be drilled and tapped to mount•Cannot be mounted significantly off vertical


Across the Line Starter - IEC

Advantages•Available up to 860A, AC-3•Modular family includes:

•Overloads•MSP’s•Mounting Systems/Busbars

•Touch safe design•Versions tested for various applications•Space saving designs, mini versions available•DIN rail mounted•Global approvals

Limitations•Life span is application dependent•Typically 1 million operations at rated load•Limited field serviceability

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Data NEMA IEC 18 AmpDescription Size 1 AC-3

HP Rating 10HP 10 HP

Life Operations 10 mil 2 mil

List Price $204 $130

Panel Area Required 21.4 in2 7.1 in2

IEC vs. NEMA Cost / Size / Life Comparison

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Data NEMA IEC 18 A IEC 38 ADescription Size 1 AC-3 AC-3

HP Rating 10HP 10 HP 25HP

Life Operations 10 mil 2 mil 10 mil

List Price $204 $130 $210

Panel Area Required 21.4 in2 7.1 in2 14 in2

Life Comparison Equalizing Life


Across the Line Starter – Definite Purpose

Advantages•Available up to 90A, 1,2or 3 pole versions•Specially tested to HVAC standards•Fast-on connections•DIN rail mounting available•Economically priced approx. 2/3 IEC $•UL and CSA approvals

Limitations•Life span is application dependent•Panel normally drilled and tapped•Very limited field serviceability•No matching overloads


Across the Line Starter – Solid State

Advantages•Available up to 50A, AC-1 or 15A, AC-3•No moving parts•Touch safe design•Ideal for high duty cycle or high vibration applications•Ideal replacement for mercury contactors•DIN rail mounted•Global approvals

Limitations•Heat dissipation can be an issue•No field serviceable parts•No matching overloads•No aux contacts•Approx 1.5x IEC $


Across the Line Starter – Vacuum

Advantages•Available up to 500HP @ 480 VAC, 600A•Long contact life due to vacuum•Ideal for high duty cycle applications•UL, CSA approvals

Limitations•Physical size may be an issue•Approx. 2x IEC $•Limited offering starting at 200A


Overload Protection

Overload Relays for ATL Starters


Motor running overcurrent protection

NEC article 430 - part C CEC rule 28-200 Reduce fire hazard

Comply with NEC/CEC

NEC Article 430


Eutectic Alloy Type

Type W Heater Elements

• Adjust trip setting by installing various rated heater elements• Manual Reset only


Thermal Memory

Type W Heater

Elements

Eutectic Alloy

Thermal MassResistance Element

To MotorTo Power

Ratchet Stud

Pawl to Mechanism Which Controls Relay

Contacts


Eutectic Alloy Overload Relay Operation

Reset Position Tripped Position

EUTECTIC ALLOY

HEATER

PAWLRATCHET

PIVOT

CONTACTACTUATOR

CONTROLCIRCUIT

TOSTARTER

COIL

POWERCIRCUIT

POWERCIRCUIT

CONTROLCIRCUIT

TOSTARTER

COIL


Bi-Metal Theory

Two metals with dissimilar expansion

Generated heating causes deflection

Adjustable trip setting

Manual or automatic reset

Bi Metallic


Basic Electronic Overload

Advantages• Increased accuracy• Enhanced performance• Easy to select and apply• Greater application flexibility


Product Overview

Feature Overview

Latching MechanismInsert MoldedPower Stabs

Reset ButtonTest Button

DIP Switches(193-EE, 592-EE only)

FLA Setting Dial

Mechanical Trip Actuator

Trip StatusIndicator

Control Terminals95 & 96 / 97 & 98

Load Terminations


Product Overview

Wide 5:1 Adjustment Range• Application flexibility• Simplified product selection with a minimized number of catalog devices,

greater overlap• One device covers the range of 4 bimetallic overloads or 19 eutectic heater

elements

0.1A 90A

E1 Plus

Bimetal


Proper Overload Protection

vs. Motor Life


Reduced Voltage Starters

• Basic Functionality– Reduce inrush current during motor start– After start motor runs at full rated speed– Reduced starting torque = reduced mechanical wear – May provide energy savings if peak charges are an issue

• Electromechanical– Part Winding

• Used with special motors with parallel windings• Reduced starting torque

– Wye – Delta• Used with 6 lead delta wound motors• Reduced starting torque

– Autotransformer• Reduced starting torque vs. ATL but most per amp of above

• Solid State– Uses SCR’s to chop voltage peaks during start up– Electronic controls on SCR’s enable flexible starting profiles


Economy Solid State Soft Starts

Advantages

• Up to 100HP @480VAc, 135A•Start ramp time selectable from 2 – 30 sec• Initial torque can be selected from 15% to 65%• Kick start can be selected to provide breakaway torque• Built in Overload protection• Diagnostics via flashing LED• Remote status via alarm contact• Ramp to stop

Limitations• No field serviceable parts

• Limited starting torque• 4 – 10 starts per hour


SMC-Flex

Advantages

• Up to 400HP @ 480VAC, 480A•Programmable ramp time• Special pump control algorithm available• Preset slow speed capable• Can do full voltage start• Built in Electronic Overload protection• Diagnostics via local message display or comms• Remote status via alarm contacts or comms• Smart motor braking optional;

Limitations• Limited starting torque

•

Full Featured Solid State Soft Starts


Variable Frequency Drives

• Basic Functionality– Offers total speed control including ramp

up and down– Speed controlled by changing frequency of

power to motor– Speed control may result in energy savings

• Component class drives– Power Flex 4– Power Flex 40– Power Flex 400

• Architecture Class Drives– Power Flex 70– Power Flex 700


Optimized for machine-level and stand-alone control• Most economical

Allen-Bradley offering in its power, performance & feature segment

• Simple selection, set-up, & operation

• Industry-standard RS-485 communications capabilities

• Industry-standard power structure features & installation options P

erfo

rman

ce /

Fu

nct

ion

alit

y

Power Rating (HP @ 460V)

5 10 20 50 200

PowerFlex 400 PowerFlex 40

PowerFlex 4

100

“4-Class”

Products

“Component Class” Drives


Component Drive Applications

• Provides a smooth accel/decel – no jerky motion

• Fixed acceleration using variable frequency– Important when synchronizing machines or

processes

• Speed changes “on the fly”• Communication status across network• Critical stopping criteria –

– For repeatable and accurate “in position” applications


Rockwell Automation Strengths

• The most simple to use product in its class• Integral keypad with control keys and local pot active out of the box• DIN rail mounting, small package size, Zero Stacking

• Same integral keypad as PowerFlex 4• Expanded I/O, sensorless vector control, add on communications options

and timer/counter/Step Logic functionality

• PowerFlex 400 is the HVAC drive with standard features aimed at the centrifugal pump and fan marketplace


Integral LED Keypad Simplifies Start Up

• 4 digit LED display indicates parameter number or value • LED indicators for run and direction status• LED indicators for units of parameter values• Programming keys similar to all other PowerFlex products• Three simple programming groups

– Display Group– Basic Group– Advanced Group


Drive Commissioning Made Simple

• Just hook up your power wiring and control the drive from the integral keypad

– Control keys are active allowing out of the box operation. Status indicators above start key and speed pot indicate when active.

• 10 most common application parameters contained in Basic Program Group to simplify programming

– P031 Motor Nameplate Voltage– P032 Motor Nameplate Frequency– P033 Motor Overload Current– P034 Minimum Frequency– P035 Maximum Frequency– P036 Start Source– P037 Stop Mode– P038 Speed Reference– P039 Accel Time 1– P040 Decel Time 1


PowerFlex 40 – Increased Performance

• Excellent motor control, thru 7.5 kW / 15 HP– V/Hz or Sensorless Vector (SVC) modes

• Communication– Integral RS485 serial communication– Add-on communication adapters

• Expanded I/O– Analog output– 2 digital outputs

• Logic Functions– Timer– Counter– StepLogic

• Similar to PowerFlex4− Common parameter structure & set-up– Integral user interface– Common “4 Class” accessories


Relative Cost Comparison 5-50HP

DP IEC NEMASS

Contactor

SS Reduced Voltage VFD

5HP 0.7 1.0 2.3 1.5 3.7 8.0

15HP 0.6 1.0 3.4 1.0 3.1 11.8

30HP 0.8 1.0 4.5 3.8 8.5

50HP 0.9 1.0 2.2 4.3 13.0


Relative Cost Comparison 75 – 200HP

IEC NEMA Vacuum

SS Reduced Voltage VFD

75HP 1.0 3.9 5.5 5.5 12.9

100HP 1.0 2.4 3.3 4.4 9.6

150HP 1.0 3.1 2.0 3.1 8.0

200HP 1.0 2.7 3.1 3.0 11.2


Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 34

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Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 1 Motor Starting Technologies Jack Smith – SYD Joe Pickell - RA