Application Notes

HOW TO SUCCESSFULLY APPLY

MEDIUM VOLTAGE SOFT STARTERS

HOW TO SUCCESSFULLY APPLY MEDIUM VOLTAGE STARTERS

Application Challenge

The selection of a suitable selection of a suitable starting method for a

motor/load combination is becoming increasingly important as additional
loads are added to existing utility and distribution systems. In the past,
ample capacities were available in the utility networks to support the needs
of industry. As well, the distribution systems of most North American
industries were established during the industrial and technological boom
years preceding the Second World War. In the 1990s, the viability for the
construction of new electrical generation plants became prohibitive. With
lower North American utility generating capacity and increased risks
involved in the de-regulation of this utility, stability and voltage drop
concerns have become very real issues that face all electrical power
consumers.
Problem
Full voltage starting of motors can produce objectionable voltage flicker,
mechanical stress to gear boxes or belt drive systems and create pressure
surges or water hammer in pumping applications. Starting a motor at
reduced voltage can help reduce or overcome these problems. 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.

Application Solution

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. The source of power and the effects the motor starting currents will
have on the source and the stability of the system voltage.
2. The starting and breakdown torque characteristics of the motor (motor
speed torque characteristics)
3. The motor starting characteristics (torque) that correspond to the motor
best suited to the load characteristics at full load and speed
4. The starting characteristics of: motor torque load torque, accelerating
load torque (load inertia) the motor starting, accelerating and running
torque on the driven load
5. The available short circuit capacity of the distribution system
6. The operating speed range of the connected load
7. Process considerations: shock, vibration, mechanical hammer, the
control and maintenance of different starting methods.
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.

HOW TO SUCCESSFULLY APPLY MEDIUM VOLTAGE STARTERS

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. 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.
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.
Figure 1 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.

Im age Here

Figure 1 Motor Current Speed Curve

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.

HOW TO SUCCESSFULLY APPLY MEDIUM VOLTAGE STARTERS

Figure 2 shows a set of torque-speed curves for a typical variable torque

load (such as a fan, blower or unloaded centrifugal compressor) and
induction motor that could be coupled to 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.

Image Here

Figure 2 Torque / Speed Curves

The examples shown in Figure 2 is the closest to 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 current 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
Figure 3.

HOW TO SUCCESSFULLY APPLY MEDIUM VOLTAGE STARTERS

Im age Here

Figure 3 % Voltage / Speed Curves

Reduced Voltage Starting

There are three main reasons to apply reduced voltage to medium voltage
motors:
1. To reduce the mechanical effect of across the starting and stopping
(Soft Start/Stop)
2. To limit the inrush current inherent with full voltage starting (Voltage
Ramp/Current Limit)
3. To reduce the effects of pressure surges and water hammer in pumping
systems. (Pump Control)
Mechanical Shock
This reason for applying reduced voltage has various different names; it
can be called mechanical shock, mechanical stress, or various other names.
The effect is the same. When a medium voltage motor is started at full
voltage the torque being applied from the motor to the driven load rises to
a very high value almost immediately. This can cause damage to the
bearings in the motor or the load, the rotor of the motor or to the
mechanical coupling method which connects the motor to the load. The
load itself can sustain damage depending on what the application may be.
In the case of conveyor application if the load is started to quickly the belts
of the conveyor can be stretched or broken. If the motor is connected to
the load via chains or belts these coupling means can be damaged as well
by sudden starting techniques.

HOW TO SUCCESSFULLY APPLY MEDIUM VOLTAGE STARTERS

Utility Restrictions
As utility power systems continue to be run at maximum capacity the effect
of starting medium voltage motors across the line can put stress on the
factorys power distribution system. The lights go dim, process control
systems can fail or trip out or you may be restricted as to when and how
often you are allowed to start the motor.
Load Related Reasons
Many of our MV SMC Flex applications have been purchased based on
system performance improvements. By soft starting the load the customer
may see improvements in the way the equipment performs. For example,
when a soft starter is applied to an agitator by slowing ramping up the
speed of the motor the material being agitated tends to splash less and
causes fewer problems than when started across the line. In the case of mill
applications the material will start to move slower than when started across
the line and cause less wear on the driven load. The ways in which a soft
start can improve system performance are only limited to the number of
applications that the end user can think of. New uses are being thought of
and applied all the time.
Torque Requirements
It is important to reiterate that when the voltage is reduced when 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, it will not start that same
load under reduced voltage conditions.
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.
Reduced voltage starting can be accomplished in several different ways.
Reactor Starting
This method also reduces the voltage, current and torque to the motor
according to the reactor tap setting. It is possible to reduce the motor
terminal voltage as required by placing a primary reactor in series with the
motor windings, for a period during starting. 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.

HOW TO SUCCESSFULLY APPLY MEDIUM VOLTAGE STARTERS

Autotransformer Starting
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 autotransformer. There are two
very distinctive characteristics of an autotransformer starter.
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 turn 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 turn ratio also represents the voltage ratio, the
starting current is reduced by the square of the turn 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).
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 field coupling, eddy current drives and
clutches. The stepless ramped acceleration and deceleration capabilities of
these types of starter reduces the inrush currents to the motor, eliminating
transitional shocks to the load and reducing voltage flicker on the
distribution system.

HOW TO SUCCESSFULLY APPLY MEDIUM VOLTAGE STARTERS

Selection of Appropriate
Starting System

The selection of an appropriate starting system requires the reviewer to

compare or weigh the importance of several factors.
Cost and Economics: When determining the starting method, the
economics of the decision can also provide important tips to the selection
of an appropriate controlling means.
Maintainability: The capabilities of the mechanical and electrical support
facilities and personnel can have an important impact on the starting
method determination.
Remote Control Requirements: As businesses become increasingly more
competitive, the reductions in the area of personnel related to the control
and operation of industrial processes are becoming dramatic. This required
reduction of personnel has subsequently hastened the development of the
remote control capabilities of modern motor control equipment. In many
cases, production flow and efficiency rate adjustments can be critical to the
quality of the end product. For example in the case of remote pumping
stations, the ability to control the speed of a booster pump, based on the
product in the line at the time, can allow a remote location to monitor and
adjust flow rates to maximize the capacity of the pipeline.
Process Control Requirements: In todays competitive environment,
industry is endeavoring to continually improve processes to produce high
quality products, at accelerated periods, at the least possible cost. If the
process requires variation of speeds, a controller that will vary the motor
speed would be appropriate. If depressed distribution voltage, during
motor start cycles, is an issue, a solid state or other reduced voltage starting
method may suffice.
Physical size restraints: The limitations of available physical floor space
could be a major concern when retrofitting new equipment into an existing
control area. The physical construction of equipment housing the newer
technology may not be suitable incorporated within existing facilities.
Careful consideration may be required for the removal of heat generated by
semi-conducting devices, printed circuit cards, transformers and other
electronic control devices. Cooling systems may be needed to aid in the
maintenance of a suitable environment for these types of equipment.
Ease of use: One consideration that is sometimes overlooked is the
capabilities of the personnel required to service and maintain the
equipment. Simpler more traditional starting means may be suitable where
basic personnel training levels are maintained. The simpler relay control
logic systems may be adequate for the system configuration required for
the specific process.

Medium Voltage Products, 135 Dundas Street, Cambridge, ON, N1R 5X1 Canada, Tel: (1) 519.740.4100, Fax: (1) 519.623.8930, www.ab.com/mvb
Publication 1560E-WP023A-EN-E November 2006

Copyright 2006 Rockwell Automation, Inc. All rights reserved. Printed in Canada.