Motor Starters

When the stator windings of an induction motor are connected directly

to its 3-phase supply, a very large current (5-8 times full load current)
flows initially. This surge current reduces as the motor accelerates up
to its running speed.
Induction motors can be Direct-on Line (DOL) started in this way. The
starting current will not cause damage to the motor unless the motor is
repeatedly started and stopped in a short space of time. This is called
fast cycling. When very large motors are started direct-on-line they
cause a disturbance of voltage (voltage dip) on the supply lines due to
the large starting current surge. This voltage disturbance may result in
the malfunction of other electrical equipment connected to the supply.
To limit the starting current some large induction motors are started at
reduced voltage and then have the full supply voltage reconnected
when they have run up to near rated speed.
Direct-on-line starting is the method most commonly used, the most
usual consideration being whether the generator and the distribution
system can withstand the starting current without excessive voltage
dips. In the case of loads involving considerable inertia, such as
centrifugal oil separators, the starting time may also be a factor. In
case of doubt, the motor manufacturer should be consulted.

The starting current as we have already seen may be five to eight

times the full load current, and the heating of the windings is
proportional to the square of the current. At starting it will therefore be
25-64 times normal. Furthermore, at the instant of start there is no
windage and no radiation. Therefore a very long starting period may
result in overheating.
For these reasons it is also undesirable to make repeated successive
starts without intervening periods for cooling.
The contactor coil is connected in series with a start button, stop
button and overload trip contacts. This is called the control circuit and
is energised from two lines of the 3-phase supply usually via a stepdown transformer. When the start button is pressed the control supply
is connected to the contactor coil. The contactor closes and then starts
the motor. When the start button is released its contacts spring open.
An auxiliary contact on the contactor keeps the contactor coil
energised after the start button is released.
Pressing the stop button breaks the control circuit to the contactor coil;
the contactor trips and the motor stops.
If the motor takes too much current because it is mechanically
overloaded or stalled, the overload coils will either magnetically or
thermally open the overload trip contacts which will stop the motor

and prevent overheating. Note, the correct term is overcurrent rather

than the commonly used overload.
Reduced voltage starting is used for large motors driving loads like
cargo pumps and bow thrusters. Two methods of reduced voltage
starting are star-delta starting and autotransformer starting.
After DOL starting, the next most common method is the star-delta
method.

Both ends of each phase of the motor starter windings must be

brought out and connected to starter. In the start position the windings
are connected in star; in the running position they are reconnected in
delta. The voltage across each phase winding in the start position is
58% (1/3) of line voltage, with consequent reduction of starting
current. The starting torque is also reduced to one-third of that which
would obtain with d.o.l. starting. With a single-cage or double-cage
rotor of average performance, this represent about 80% of full-load

torque, assuming normal line voltage, but if there is appreciable line

drop the torque will be proportionately lower. These factors must be
taken into account when deciding whether star-delta starting is
acceptable for the driven machine. It will be acceptable for centrifugal
fans and pumps if, in the latter case, the friction at starting is not
excessive.
When the operating handle is placed in the start position the motor
stator windings are connected in star across the supply. As the motor
approaches normal running speed the operator must quickly change
the handle to run position which changes the motor connection from
star to delta. If the operator does not move the handle quickly from
start to run the motor may be disconnected from the supply long
enough for the motor speed to fall considerably. When the handle is
eventually put into the run position the motor will take a large current
may be large current and accelerate up to speed again. This surge
current may be large enough to cause appreciable voltage dip. The
prevent this, a mechanical interlock is fitted to the operating handle.
The handle must be moved quickly from start to run otherwise the
interlock jams the handle in the start position.
An automatic change over is preferable and this is achieved by using
contactors.

Star-Delta starter sequence:

Operator closes motor isolator IS then presses start button.
Start button connects the supply to contactor coil S.
Contactor contacts S close and auxiliary contacts S1 close.
L close, motor windings are star connected to 3-phase supply, motor
starts.
Auxiliary contacts L1 close at the same time as contactor contacts L.
The operator may now release the start button since supply to L is
maintained through L1. After a time interval which allows the motor to
run up to speed, auxiliary contacts L2 and L3 close.
Contactor coil S is de-energised and its contacts S open; so do the
auxiliary contact S1. Contactor coil D is energised and the motor is now
delta connected to the 3-phase supply. In some cases a mechanical
interlock is fitted between the contactor contact S and D so that both
cannot be closed at the same time.
The auto-transformer starter is more expensive than two type so far
described and is generally used only for the larger types of motor. It is
suitable for motors in which each end of the three phases is not
brought out, and which would therefore be unsuitable for star-delta

starting. The starting conditions depend on the position of the tapping

on the transformer winding, i.e. on the secondary voltage. Usually
three or more tappings are provided so that there is a choice of
starting conditions such as 40, 60 or 75% of line voltage. The starting
torques on these different tappings can be estimated as they are
proportional to the square of the voltage. On the 60% tapping the
torque will b approximately the same as with star-delta starting, and on
the 40 and 75% tapping it will be proportionately lower and higher
respectively.
Starting large motors with long-run up periods demands a very high
current surge from the supply generator. This causes a severe voltage
dip which affects every load on the system. Reduced voltage starting
will limit the starting surge current.
One way to reduce the initial voltage supplied to the motor is to step it
down using a transformer. Then, when the motor has accelerated up to
almost full speed, the reduced voltage is replaced by the full mains
voltage. The transformer used in this starter is not the usual type with
separate primary and secondary windings. It is an autotransformer
which uses only one winding for both input and output. This
arrangement is cheaper, smaller and lighter than an equivalent doublewound transformer. For induction motor starting, the autotransformer
is a 3-phase unit, and because of expense, this method is only used
with large motor drives, e.g. electric cargo pumps.
The autotransformer with its range of tapping points gives a set range
of starting voltages to limit the motor starting surge current to a
reasonable value.
As with the star-delta starter, the autotransformer may use what is
called an open transition switching sequence or a closed transition
switching sequence between the start and run conditions. In the
former, the reduced voltage is rapidly reconnected to the motor.
The circuit diagram below shows a manually operated open transition,
autotransformer starter.

The problem with open transition is that a very large surge current can
flow after the transition from reduced to full voltage.
An arrangement which overcomes the transition switching problem is
the closed transition Korndorfer starting method. A typical circuit is
shown below.

When the start button is pressed the first stage contactor coil is
energised which closed the main 1st contacts and also 1st/1 and 1st/2.
The timer relay coil and the second stage contactor coil are also
energised. The main 2st contacts close, which applies a reduced
voltage from the autotransformer to the motor windings. The motor
starts. After a preset time interval the times relay opens tr/2 which
drops out the second stage contactor. The star point of the transformer
is opened by 2st so that transformer action no longer takes place. The

transformer winding no just acts as an inductive voltage dropping

impedance in the supply lines to the motor. The voltage applied to the
motor is now higher than before but is still less than the full supply
voltage. After a further time interval the timer relay closes tr/3, which
energises the changeover relay. The changeover relay closes the run
contactor which puts full voltage on to the motor. Auxiliary contacts
rn/2 and rc/1 on this contactor drop out the first stage contactor and
maintain the supply to the run contactor coil, respectively. The stop
button or overcurrent relay trips out the run contactor to stop the
motor.
The windings of the autotransformer are short-time rated and the
starting period must not be unduly prolonged. The rating for ordinary
during is usually suitable for not more than two starts per hour. After
two consecutive starts a minimum subsequent cooling period of 60
minutes is necessary. If more frequency starting is required, starters
rated for intermittent duty (40 starts per hour) should be specified.
Electronic starters often referred to as soft start, are finding
acceptance in the marine industry. Solid-state technology is employed
to provide a method of starting without the current and torque surges
mentioned previously. Thyristors or a combination of thyristors and
diodes are used to control the current flow during motor starting. The
basic circuit diagrams for these two alternatives are shown below.

The electronics for controlling the firing of the thyristors is normally

accommodated on a small printed circuit board within the motor
controller. Although the thyristor/diode configuration is cheaper it has
the disadvantage that it generates third and even harmonic currents in
the motor windings, whereas the all-thyristor arrangement restricts the
even harmonics.
With this type of starter there are normally three adjustments that
have to be set to suit the drive machinery:
1. Voltage ramp - This sets the time for the starter to achieve full
voltage output. It should be noted that the ramp time is the time taken
for the output voltage to reach its maximum and not for the motor to
reach its full speed.
If a motor is lightly loaded it may well achieve full speed before full
voltage is applied.

2. Current limit - This adjustment is used to prevent the starting

current exceeding a preset value. Because torque is proportional to the
square of the current it must be set sufficiently high that adequate
torque is developed to accelerate the load from rest.
3. Initial firing angle - It is often important that a drive should start
as soon as voltage is applied, e.g. if the drive is standby to a duty unit.
If the initial firing angel is set too small there will be a delay in starting
the drive until the voltage has been ramped to a value permitting
sufficient torque to be developed to accelerate it from the rest. If the
initial firing angle is set too large the load may be suddenly grabbed
rather than accelerated smoothly.
Triacs can also be used for electronic starters. However, since they
have relatively low current ratings and breakdown voltages they are
generally suitable only for low-current low-voltage applications
Demand separate