INDUCTION MOTORS FOR FARM APPLICATIONS

Pavel Somavat, Amarjit Kalra and R K Jhorar

College of Agril. Engineering & Technology, CCS HAU, Hisar

Three phase induction motors also called asynchronous machines are preferred in irrigation and
tube-well motors because of their low cost, rugged construction, high efficiency, good power
factor and low maintenance. Induction motors (Fig. 1) are available in various specifications
depending upon principle of operation, power output, construction, power supply and speed. One
of the major differences is their availability with different type of rotors i.e. i) Induction motor
with squirrel cage rotor and ii) Induction motor with Phase wound rotor.

1. Squirrel cage rotor: The induction motors employing these kinds of rotors are called squirrel
cage rotor type. It is rugged in construction consisting of a laminated cylindrical core with semi-
closed slots at the outer periphery. These slots contain copper or aluminum bar conductors which
are short circuited by copper or aluminum rings. The rotor winding is shorted and there is no
option for adding any external resistance.

2. Phase wound rotor: This is also known as slip ring rotor and consists of a laminated
cylindrical core having semi closed at the outer periphery and hosts a three phase insulated
winding. Rotor is wound for the same number of poles as that of the stator. The terminals are
connected together forming star point and the three start terminals are connected to three copper
slip rings fixed on the shaft. Here depending on the requirements, an external resistance can be
added to the rotor.

Figure 1. Basic
constructional features of an induction motor

Out of the above two, the three phase induction motor with a squirrel cage rotor is the motor of
preference when it comes to the application in irrigation pumping. However it has certain
drawbacks also, firstly a speed of the induction motor cannot be varied without sacrificing
efficiency. Secondly their start-up requires up to three times the normal operating current which
is a problem in itself as it causes a huge drop in supply voltage system affecting other users.
However electronic devices called starters are available to offset this problem.

1. Types of Starters
a. Star/Delta Starter: This is the simplest and most widely used method of starting. The
windings of the motor are connected in star (wye) at the start-up, thereby reducing the voltage
applied to each phase to 58% of its Direct Online Startup (DOL) value. When the motor speed
approaches its running value, the windings are switched to delta (mesh) connection. In this case
the current drawn from the supply is approximately one third of that drawn in a DOL start
however at the same time the starting torque is also reduced to one third of its DOL value.

b. Autotransformer Starter: In case where the initial torque requirements are larger, a 3 phase
Autotransformer starter is used (Fig. 2). Each phase of an autotransformer consists of a single
winding on a laminated core. The mains supply is connected to the coils and one or more sliding
contact is provided to give a reduced voltage output. At the start-up the motor connected to the
reduced voltage output, and when the current has fallen to the running value the motor is
connected to full voltage. Hence the start-up current is regulated with this measure.

Figure 2. Illustration of an autotransformer starter

c. Resistance /Reactance starter: By addition of three resistors or inductors of proper value in

series with the motor, the starting current can be reduced but only at the expense of starting
torque. For example, if the current is reduced to half its DOL value, the motor voltage will be
halved, so the torque will be reduced to only 25% of its DOL value. This approach is thus less
attractive in terms of torque per ampere of supply current than the star/delta method. However
the motor speed increases and its effective impedance rises, the volt drop across the extra
impedance reduces, so the motor voltage rises progressively with the speed, thereby giving more
torque. When the motor is up to speed, the added impedance is shorted-out by means of an auto
or manual contact.
2. Selection of electric motor
Selection of the motor depends upon the applications and also on the conditions in which the
motor is operated. Usually irrigation and pumping applications require three phase induction
motors in the range of 5 HP to 20 HP. Other factors which influence the selection of motors are
as under:

a. Mounting: Electric Motors can be differentiated based on the direction of axis of rotation.
There are horizontally mounted and vertically mounted motors. Vertically mounted motors can
be used for vertical turbine pumps where a stand-by diesel engine can be attached in case of
power failures. Vertically mounted motors are mostly used with vertical turbine pumps, mixed
flow pumps and propeller pumps where the propeller is mounted vertically. These are mainly
three phase induction motors with squirrel cage rotor mostly employed in agricultural
applications.

b. Insulation System and type of Duty: Insulation system of a motor is one of the most vital
components which are critical for the flawless operation of the motor. The maximum
temperature a motor can with stand depends upon the thermal stability of the insulating material.
With a higher thermal stability, same motors can be rated for higher power output. Motors are
classified into various different types depending upon their insulation system. For typical
agricultural applications, Class H type three phase induction motors with squirrel cage rotor have
been recommended. These motors have a high limiting temperature of 180° C which makes them
perfect of varying degree of applications.

During their operation, the motors tend to get heated. This heat has to be dissipated so
as not to overheat the windings and burn them. Only when a motor works continuously, the heat
dissipated is equal to the heat generated. Since irrigation related applications require the motor to
be operated continuously, Continuous duty type motors must be used in pumps.

3. Motor Protection
Conditions like overloading, prevalence of under-voltage and problem of single phase often
affect the normal operation of the electric motors and cause permanent damage to them. In order
to protect the motors from the ill effects of these, a number of protective elements are designed
and to ensure safe operation of the motors. Protective features for overloading and under-voltage
are incorporated into the starter itself.

i) Overload protection: A motor may get overloaded because of excessive load due to some
jammed part or presence of a tight belt. Also if the pulley on the pump is not aligned with the
motor pulley a motor may get over-loaded. In order to prevent a motor being over-loaded two
types of protection devices are used:
a. Electro-magnetic type consists of an electromagnet connected in each line wire and motor. If
excessive currents oh high magnitude flow for a sustained period, the tripping device is
activated. Extreme care must be taken in such kind of devices to ensure the oil used confirms to
the manufacture specifications and also the level of the oil is optimum failing which the device
may trip erroneously.

b. Thermal type overloading device consists of small heater and a bi-metallic strip. If the
current drawn by the line exceeds a certain threshold, the heated connected in series gets heated
depending upon the amount of current flowing through it. The bi-metallic strip gets heated and
because of different coefficients of expansion it gets twisted. This strip is used to provide circuit
connection and because of twisting the connection is broken. Hence the motor is protected from
overheating.

ii) Under voltage protection: An under voltage protection device is consists of a coil with an
iron piece to make or break the connection when the starter switch is pressed. Within the
specified voltage levels, the iron piece is attracted and the circuit is complete however at low
voltages the coil does not create the strong enough electromagnetic force to attract the coil and
hence the connection remains short. Hence the motor is stopped when the voltage level falls
below a certain threshold.

iii) Protection from single phasing: Sometimes because of the failure of a phase out of the three
phases only two phase supply is available, this condition is known as single phasing and has the
potential to do great damage. Here the two available phases try to provide the same energy and
therefore the amount of current flowing through these almost becomes two times. This may
result in overheating and burning of the windings. A phase guard device employed consists of
three identical current transformers whose primary windings are connected with series with the
three lines. The corresponding secondary windings are connected to the circuit which controls an
output relay. In case of single phasing the control gear is tripped preventing the motor damage.

4. Importance of power capacitors:

When an inductive load like an induction motor is attached to an alternating supply, a phase
difference is observed in the supply voltage and current. Here the voltage leads the current
decreasing the value of the power factor which is one when both of them are in phase. In actual
practice the power factor is normally below 0.8 which is not recommended by the power
supplier. It is therefore advisable that the users employ power capacitor between the main switch
and the starter to increase the power factor. An addition of a power capacitor will decrease KVA
demand from the supply and ensure that all the consumer get a better voltage regulation and
more power for same kVA. In case of motors ranging from 5-10 HP, capacitors of 2-4 kVAR
must be employed for better overall performance. Hence all the users are strongly recommended
to use power capacitors in their installations.
5. Installation of Electric Motors
a. Location: While selecting motor location, consideration should be given to environment and
ventilation. An appropriate motor with proper enclosure for the operating conditions should be
selected. Care should be taken that air surrounding the motor should not exceed 40°C. There
should be a free flow of air around the motor. The motor should never be placed in a room with a
hazardous process, or where flammable gases or combustible material may be present. Fully
enclosed motors may be installed where dirt, moisture and corrosion are present, or in outdoor
locations.

b. Floor mounting: Motors should be provided with a firm, rigid foundation in confirmation
with the plane of four mounting pads. A good foundation is not only sturdy but also allows the
motor parts to be in alignment with mechanical as well as electrical connections.

c. Electrical connections: One of the most popular methods for the connection of electric
motors is using star-delta starter configuration (Fig.3). In this the power is fed to the motor
through a succession of components like main switch, capacitor and the star-delta starter. Three
light bulbs can also be connected to observe individual phases and a voltmeter is used to monitor
supply voltage. The diagram below shows the electric connections for a motor using a star-delta
starter.

Figure 3. Electrical components and connections of an induction motor

6. Earthing of the motors

Earthing is defined as a system of electrical connections to the general mass of earth. The most
important characteristic of an earthing system is the resistance observed by the earthing
electrode. Earthing is important as it provides protect to people and animals from accidental
electric shock and also for the proper functioning of the electrical system. Soil resistivity plays
and important part in designing an earthing system for electric motors. In India all the motors
installations are obligated by law to have a proper earthing circuit. There are two major types of
earthing employed in farm sector known as pipe earthing and plate earthing. Pipe or Rod
earthing is suitable for low power motors ranging upto 7 HP while larger motors require Copper
plate earthing. However because of cost considerations, mostly the pipe type or rod type earthing
is employed by the farmers in India. The Fig. 4 below illustrates a pipe earthing system.

Figure 4. Schematic diagram of Pipe or rod grounding

7. Maintenance and troubleshooting

Following measures must be taken before working on the motor for maintenance and
troubleshooting work. Also a person working on the motor must be competent enough to work
with it.

 Disconnect power before working on motor or driven equipment.

 Discharge all capacitors before servicing motor.

 Keep hands and clothing away from moving parts.

 Never attempt to measure the temperature rise of a motor by touch.

  Electrical repairs should be performed by trained and qualified personnel only.

 Failure to follow instructions and safe electrical procedures could result in serious injury
or death.

For trouble shooting purposes, Table 1 provides the guidelines for identification of general
problems faced in motors and their repairs. One must however note that this table only provides
rough estimation about the probable causes. One must consult a qualified mechanic for getting
the things in place.

Table 1.

Trouble Probable Cause Steps to take

Motor fails to start Blown fuses Replace fuses with
proper type and rating

Overload trips Check and reset overload

in starter.

Improper power supply Verify that power

supplied agrees with
motor nameplate and
load factor.

Rotor defective Look for broken bars or

end rings.

Motor may be Reduce load.

overloaded

Motor stalls One phase may be open Check lines for open
phase.

Wrong application Change type or size.

Consult manufacturer.
Overload Reduce load.

Low voltage Verify that nameplate

voltage is maintained.

Motor does not achieve Starting load too high Check load motor is
full speed supposed to carry at
start.

loose rotor Broken rotor bars or

 Look for cracks near the
rings. A new rotor may
be required as repairs
are usually temporary.

Open primary circuit Locate fault with testing

device and repair.
Motor takes too long to Excessive load Reduce load.
accelerate and/or draws
high current
Low voltage during start Check for high
resistance. Adequate
wire size.

Defective squirrel cage Replace with new rotor.

rotor

Wrong rotation Wrong sequence of Reverse connections at

phases motor or at switchboard.

Motor vibrates Motor misaligned Realign.

.
Weak support Strengthen base.

Defective bearings Replace bearing.

Polyphase motor running Check for open circuit.

single phase

Hot bearings ball Insufficient grease Maintain proper quantity

of grease in bearing.

Deterioration of grease Remove old grease,

or lubricant wash bearings
contaminated thoroughly in kerosene
and replace with new
grease.

Excess lubricant Reduce quantity of

grease, bearing should
not be more than 1/2
filled.

Overloaded bearing Check alignment, side

and end thrust.