Microcontroller based Protection

of

Three-Phase Induction Motor

Project Report

Submitted by

Rohan Prakash Raunak

Reg. No.: 130906562 Reg. No.: 130906572
Under the guidance of

Mr Ganesh Kudva
Assistant Professor - Senior Scale,E&E Engg. Dept.

In partial fulllment of the requirements for the award of the degree of

BACHELOR OF TECHNOLOGY
IN
ELECTRICAL AND ELECTRONICS ENGINEERING

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

MANIPAL INSTITUTE OF TECHNOLOGY

(A Constituent College of Manipal University)

MANIPAL 576104, KARNATAKA, INDIA
April 2017
 DEPARTMENT OF ELECTRICAL AND ELECTRONICS
ENGINEERING
MANIPAL INSTITUTE OF TECHNOLOGY
(A Constituent College of Manipal University)
MANIPAL 576 104 (KARNATAKA), INDIA

CERTIFICATE
This is to certify that the project titled Microcontroller based Protection of
Three Phase Induction Motor is a record of the bonade work done by Rohan

Prakash (Reg. No.:130906562) and Raunak (Reg. No.:130906572) submitted in

partial fullment of the requirements for the award of the Degree of Bachelor of Tech-
nology (B.Tech.) in Electrical and Electronics Engineering (E & E Engg) by Manipal
Institute of Technology, Manipal, Karnataka (A Constituent College of Manipal Uni-
versity), during the academic year 2016-17.

Mr Ganesh Kudva Dr. Savitha G. Kini

Assistant Professor - Senior Scale Head of the Department

Dept. of E & E Engg Dept of E & E Engg.
 ACKNOWLEDGEMENTS

At the very beginning we would like to express our deepest gratitude to the
almighty for giving us the strength and the composure to complete our B-Tech
courses and prepare this report within the scheduled time.

During the period of our project work, we have received generous help from many
quarters, which we would like to put on record here with deep gratitude and great
pleasure. Words actually will never be enough to express our gratefulness.

We would like to express our gratitude respect to Dr. GK Prabhu, Director MIT
and Dr. Savitha G Kini, Head of Department of E& E Engineering and all the
Professors of Manipal Institute of Technology, Manipal for their constant guidance,
advice, encouragement every possible help in the overall preparation of this report.

We would also like to thank our project guide Mr. Ganesh Kudva, Assistant Pro-
fessor, Department of E& E Engineering for all his support and insight which has
helped us to complete our project successfully. His deep knowledge about electrical
motors made us understand the core concepts that are related to our project topic.

A special thanks also goes to all other sta members and laboratory technicians
for their support valuable suggestions during the course of project and to make
this endeavor of ours, a successful one.

Rohan Prakash Raunak

Reg. No.: 130906562 Reg. No.: 130906572
Department of E & E Engg
Manipal Institute of Technology
Manipal University
 Abstract

The purpose of this project is to distinguish between dierent faulty conditions

and protect the 3-phase induction motor as and when these faults occur.In this
project we have implemented a protection scheme for various faults that could
occur in the motor namely undervoltage, single-phasing, overcurrent and overvolt-
age. To not let these faults from aecting the motor adversely, a protection system
has been created which cuts the supply to the 3-phase induction motor when these
faults occur and brings the motor to a halt. The PLC based protection techniques
are costlier and electrical parameters such as voltage and current individually
cannot be realised by the Programmable Logic Controller (PLC) based system.
Hence, to ensure that the 3-phase Induction motor works eectively, a microcon-
troller based fault identication and protection system for the 3-phase induction
motor has been proposed. Our objective also coincides with the purpose of making
this proposed system cost eective and aordable so that it could be benecial for
small scale industries operating across the country.

The plan to achieve the above aim will be done in conjecture with appropriate
testing done at each individual level, that is with and without connecting the
motor.The relay circuit was rst tested without connecting the motor and only
when it proved eective the motor was connected and all of the above conditions
were induced in the motor and the protection system was introduced to protect
the motor from these faults. We used a hall current sensor in addition with an
instrumentation amplier to detect changes in current and step down transformers
for each phase for detecting changes related to voltage.

In conclusion, we obtained a protection system which could detect all of the above
faults and disconnect the motor with the help of the microcontroller-relay circuitry
as and when these faults occur.
Contents

1 INTRODUCTION 1
1.1 Background and Motivation . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Literature Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 BACKGROUND THEORY 5
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1.1 Single phasing . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1.2 Over voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1.3 Overcurrent . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1.4 Undervoltage . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 METHODOLOGY 8
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Motor testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Ratings of Motor under test . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Proposed Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5 Implementation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.5.1 Hardware Implementation . . . . . . . . . . . . . . . . . . . 11
3.5.2 Software Implementation . . . . . . . . . . . . . . . . . . . . 17
3.6 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4 RESULT ANALYSIS 21
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Result Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5 CONCLUSION AND FUTURE WORK 26

6 BIBLIOGRAPHY 27
List of Figures

1.1 Types of Faults-Percentage wise . . . . . . . . . . . . . . . . . . . . 1

1.2 Block Diagram of Experimental Setup . . . . . . . . . . . . . . . . 3
3.1 Motor Testing for no load and full load conditions . . . . . . . . . . 9
3.2 Detailed Block Diagram of setup . . . . . . . . . . . . . . . . . . . 10
3.3 Pin diagram of LM324 . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Block Diagram of Overvoltage fault detection . . . . . . . . . . . . 11
3.5 Block Diagram of Overcurrent fault detection . . . . . . . . . . . . 13
3.6 Testing of current sensor ACS712 . . . . . . . . . . . . . . . . . . . 14
3.7 Output of ACS712 with DC oset . . . . . . . . . . . . . . . . . . . 14
3.8 Output of ACS712 with DC oset removed . . . . . . . . . . . . . . 15
3.9 Measured test data of ACS712 current sensor output . . . . . . . . 15
3.10 Pin diagram of AD620 Instrumentation amplier . . . . . . . . . . 16
3.11 Experimental Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 Display for normal condition testing . . . . . . . . . . . . . . . . . . 21
4.2 Display for Overvoltage testing . . . . . . . . . . . . . . . . . . . . 22
4.3 Display for Single phasing testing . . . . . . . . . . . . . . . . . . . 23
4.4 Display for Undervoltage testing . . . . . . . . . . . . . . . . . . . . 24
4.5 Display for Overcurrent testing . . . . . . . . . . . . . . . . . . . . 25
6.1 Flowchart for Overvoltage sensing . . . . . . . . . . . . . . . . . . . 29
6.2 Flowchart for Undervoltage sensing . . . . . . . . . . . . . . . . . . 30
6.3 Flowchart for Overcurrent sensing . . . . . . . . . . . . . . . . . . . 31
6.4 Flowchart for Single Phasing sensing . . . . . . . . . . . . . . . . . 32

i
List of Tables

3.1 No Load Test Details . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.2 Full Load Test Details . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Motor Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Normal Condition testing details . . . . . . . . . . . . . . . . . . . 21
4.2 Overvoltage testing details . . . . . . . . . . . . . . . . . . . . . . . 22
4.3 Single-Phasing testing details . . . . . . . . . . . . . . . . . . . . . 23
4.4 Undervoltage testing details . . . . . . . . . . . . . . . . . . . . . . 24
4.5 Overcurrent testing details . . . . . . . . . . . . . . . . . . . . . . . 25
6.1 Bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

ii
Chapter 1

INTRODUCTION

Induction motors are the most widely used motors in industries because they are
rugged, reliable and economical. They require lesser maintenance when compared
with other type of motors. Its speed control is simple and exible because of
advance development made in the eld of power electronics and electrical drives.
The protection of induction motor plays an essential part in its long life and
this will in turn be benecial for the productivity of the industry where they are
being used. The small scale industries are not well equipped to include expensive
protection systems which make use of PLCs hence it is imperative that a cheap
and aordable solution is designed for protection of these motors employed in their
industries as and when these type of faults occur. Subsequently a microcontroller
based relay actuating system has been designed for protection of 3-phase induction
motors against over voltage, under voltage, single-phasing and overload.

Figure 1.1: Types of Faults-Percentage wise

1
 3 phase induction motors worldwide are plagued by various faults which dras-
tically aects their performance and they being the work-horses of industries, this
scenario in turn aects the industrial performance and productivity. Hence to
dissolve the motor from these most occurring (refer - bar graph) faults namely
overvoltage,overload,single-phasing and undervoltage, we decided to make a sys-
tem which is able to do just that. Looking at the wide use of induction motors in
almost every sector of the industrial arena, it is imperative that such a protection
system is built with impeccable accuracy and precision so that these induction
motors run up to their desired life without any hassles.

1.1 Background and Motivation

Our interest in electrical machines motivated us to take up this project on pro-

tection of induction motor. In today's scenario of "Make in India", small scale
industries provide the necessary impetus that is needed by our economy. To do
that, the prot margin of small-scale industries has to be substantial, hence our
project plans to provide a cheaper alternative protection system.

1.2 Literature Review

[1] expressed that three phase induction motor can proceed to run when one phase
of the supply left open. This might be because of any combine blowing or opening
of defensive gadget of the motor, at venture down transformer or at feeder end. At
this condition the three-phase induction motor keep on running however the motor
will warm up rapidly and it ought to be shielded by expelling it from the benet
at the moment of single staging. At the point when phase opens at venture down
transformer then again at feeder end, the stator and rotor losses increments to ten
times and the shaft output power declines to zero. However, in the event that the
single staging happens at motor terminals the losses builds twice as contrast with
steady state losses. To ensure the motor all the terminal ought to be open.

[2] have proposed the assurance of three phase induction motor in view of volt-
age estimation and is insucient to secure the motor if the blame happens at
conveyance transformer or at substation feeder. On the o chance that blame
happens at motor terminals then the voltage estimation can ensure the motor
extremely well. The current estimation gadget ought to be executed inside the
defensive gadget. They have likewise proposed a phase estimation gadget which
can quantify the phase dierence of the voltages since when the blame happens
at whatever other area as opposed to the motor terminals, then the blamed phase
will draw negative succession current and work as a voltage generator. The voltage
created is near line voltage however the estimation plan is not ready to distinguish
the blame, however the phasor dierence of the blamed phase changes.

2
1.3 Ob jectives

The main objective of the work is to make a cheap and reliable protection system
for three-phase induction motor to protect it from:
 Single-phasing
 Overvoltage
 Overload
 Undervoltage
Our project deals with protection of induction motor from 1)Single-phasing 2)Over-
load 3)Undervoltage 4)Overcurrent. From reference[1], it can be clearly understood
that single phasing can be a major problem an induction motor could face. When
phase opens at step down transformer or at feeder end, the stator and rotor losses
increases to ten times and the shaft output power decreases to negligible. But if
the single phasing occurs at motor terminals the losses become twice as compared
to steady state losses. From reference[2], we get to know that when the fault
occurs at the distribution transformer or at the feeder site, it could still be fatal
and disrupt the functioning of the induction motor. If fault occurs at the motor
terminals, then the voltage measurement can protect the motor very well. The
current measurement device should be implemented within the protective device.

Industries tried to accomplish this task of protection using PLC techniques, but
we are doing the same using microcontrollers simply because electrical parameter-
s cannot be visualized by Programmable Logic Controller (PLC) based method
whereas the microcontroller negates the above issue.

Figure 1.2: Block Diagram of Experimental Setup

3
 Here is an excerpt of the technique proposed earlier by us. here the priority en-
coder provides the digital codes needed to implement a set of protection techniques
for various problems faced by the motor. These codes are read by the microcon-
troller and it is programmed in such a way which lets it to control the functions
of the motor relay driver, which disables the motor from the supply whenever any
one of the above fault occurs in any one of its terminals.

1.4 Summary

To summarise, these protection techniques are vital for better functioning of induc-
tion motor. As induction motors are the backbone for any industry, hence these
techniques may prove paramount for glib running of most of today's industries.

4
Chapter 2

BACKGROUND THEORY

2.1 Introduction

Induction motors are the workhorses of almost every industry due to their exi-
bility, rigidity and low assembling cost. Induction motors are the solid machines.
however their damage rate is roughly 3 percent and it can be as high as 12 percent
in paper industry. repair work of the machine in the industry might be costly
hence the protection framework may upgrade the unwavering quality, individual
well being and shield the motor from over heating. The major faults which could
damage the induction motor are :
 Single phasing
 Overvoltage
 Overload
 Undervoltage

2.1.1 Single phasing

On the o chance that the state of single staging emerges amid the running of
motor, the winding of motor gets warmed because of the negative sequence current
in the faulty phase. Two phases of three phase induction motor will get control
supply in single staging condition and they deliver negative sequence current in
the faulty phase on the grounds that the inward association of three phase motor
are associated with each other. Single staging problem may emerge at three areas:
 Opening one phase of the primary side of substation transformer.
 Opening one phase of the primary side of distribution transformer.
 Opening one phase at the motor terminals.

5
2.1.2 Over voltage

The over voltage occurs when any one of the phase voltage increases above the
rated voltage and it leads to harmful eect on machine insulation. In order to
overcome this problem, over voltage sensing unit is designed. The designed unit
consists of three step down transformers to step down the phase voltage to 8V.
This step down voltage is rectied and ltered to get dc voltage proportional to the
phase voltage. This dc voltage is compared with reference voltage which has been
set by the pre-set value given to the comparator. This comparator is formed using
quad op-amp IC LM 324 and the output of the comparator is fed directly to the
micro controller .Under voltage occurs, when reduced supply voltage with the rated
mechanical load on the machine produces and inturn increases the stator and rotor
losses. In order to overcome this problem, similar design is implemented as done in
the case of over voltage condition mentioned above.Due to this increased current,
excess heating voltage sensing circuit is designed .The under voltage sensing circuit
uses the dc output from the over voltage sensing circuit and compared with the
reference voltage in the comparator wired using op-amp LM324. The only change
is the reference voltage given to the negative terminal of the comparator is lowered
to a certain value below which the problem of undervoltage occurs.The output here
is again fed back to the microcontroller which then trips the relay circuit as and
when needed.

2.1.3 Overcurrent

Over-current protection of motor means protection of the motor, if load exceeds a

specied rated value. This overcurrent in motor is generally caused by overloading
of motor . Due to this increase in current beyond the rated current then motor gets
heated up and causes harm to the motor.bearing also seizes up something locked
the motor shaft from turning. Overloading of the three phase induction motor can
also produce hot spots within the winding, which may exceed the thermal limits
of motor.In order to overcome this situation, Induction motor has a relatively
large heat storage capacity, so a short period overload cannot damage the motor
windings because a large part of heat is stored in the core, conductor mass and
in structural members . But in the case of locked rotor condition the current
rises very rapidly and a very little amount of heat transmits to the other parts
of the motor. The winding insulation thermal level may reach to its limit within
seconds.the overload sensing circuit is designed Each phase current is sensed by
using hall eect sensor module AC5712 and if current level exceeds its rated value
then comparator sends signal to microcontroller to stop the motor.

6
2.1.4 Undervoltage

On account of an under-voltage condition, the lower voltage causes the torque

created to diminish. This causes an increase in slip and lessens the speed. The
engine tries to diminish this eect by drawing more current. This over-burdens
the engine and can lead to serious over-heating.

2.2 Summary

In this chapter,the various potential faults and problems which could arise in the
induction motor were discussed, and the additional issues these faults bring to
the motor and other systems were also highlighted. The methods employed to
protect the motor when any of these faults arise was also discussed in a concise
manner. The additional faults like in the case of overcurrent(overload) create
local temperature and heat hot spots which bring about a new set of diculties
regarding temperature management in the motor core and in its windings. Hence
these methods are of utmost importance.

7
Chapter 3

METHODOLOGY

3.1 Introduction

This chapter deals with the proposed block diagram of the project, hardware
requirements for over/under voltage and algorithm of the proposed code for the
project implementation.

3.2 Motor testing

Before beginning to run the motor we thought of performing a preliminary load

test on the motor (values given in the table) to assess the limits of the motor and
whether it could run up to its rated current and beyond and as the motor was
old, we wanted to know whether it could sustain heavy loads. We also got an
estimate on the speed changes with current changes and we also calculated the
load torques developed by the motor. The temperature changes (increase) was
also monitored with increase in current and tightening of the load belt, this was
especially important as during single phasing it is known that the rate of increase
of temperature is more than the rate of increase of the current and the current
itself increases to up to 2.4 to 6 times the rated current and we can only imagine
what it might do to the temperature inside the motor. Hence to ensure there is no
unnecessary increase in temperature increase and to avoid damage to the motor
windings it was imperative that this test was performed.

Table 3.1: No Load Test Details

Voltage Current Speed

400 V 1.85 A 1496 RPM

Table 3.2: Full Load Test Details

Voltage Current Speed

400 V 3.25 A 1420 RPM

8
 Figure 3.1: Motor Testing for no load and full load conditions

3.3 Ratings of Motor under test

Table 3.3: Motor Ratings

Voltage Current Speed Power Frequency

400/440 V 3.3 A 1410 RPM 1.5 kW 50 Hz

9
3.4 Proposed Solution

Figure 3.2: Detailed Block Diagram of setup

Figure 1.1 block diagram was an alternative approach of designing the pro-
tection system because we need a more ecient protection system, which means
lesser number of equipments to get the desired output. Hence, as seen from gure
3.1 we can accomplish the same task by omitting the priority encoder altogether,
hence a more ecient and cost eective system can be designed to cater the needs
of small scale industries.

Figure 3.3: Pin diagram of LM324

This LM324 IC has four dierent comparators, hence four dierent comparisons
can be performed simultaneously and if we look at the numbers of faults from which
we are protecting the induction motor, LM324 fullls all the desired objectives.

10
3.5 Implementation

In this project, implementation done by us is mainly hardware. The only soft-

ware part is the microcontroller coding( for code look at the annexure). we have
basically implemented the protection system for overvoltage/under voltage,single
phasing,overload type of faults. In the following paragraph, the major components
which helped us complete the above tasks will be mentioned.

3.5.1 Hardware Implementation

Overvoltage/Undervoltage

Figure 3.4: Block Diagram of Overvoltage fault detection

The components used here are:
 Comparator(LM324)
 Diodes(IN4007)
 Electrolytic Capacitor
 ESA MCB-51 microcontroller kit
 Step down transformer
 DC Regulated power supply(RPS)
 Relay driver circuit
Step down transformer steps down the input ac voltage from 230V to 6V range
which is further rectied by a combination of diodes (rectier). The output of the
rectier is given to a lter circuit made by capacitors. This rectied and ltered dc
output goes to positive input terminal of the comparator and the reference voltage
supplied by the RPS goes to the negative input terminal of the comparator. The
output of the comparator is further given to the microcontroller(ESA MCB-51).
Microcontroller further actuates the relay whenever the faulty condition occurs.
11
Single phasing

When the line voltages applied to a polyphase induction motor are not equal, un-
balanced currents in the stator windings will result. A small percentage voltage
unbalance will result in a much larger percentage current unbalance. Consequent-
ly, the temperature rise of the motor operating at a particular load.The imbalance
also leads to a much larger proportion of the current imbalance. Therefore the high
temperature of the engine operates in a certain load and the voltage imbalance
ratio will be greater than to operate the engine under the same conditions with
the balanced voltages.

The term single-phasing is the term used when one phase of a three-phase sys-
tem opens. This can occur on either the primary side or secondary side of a
distribution transformer. Three-phase induction motors, when not individually
protected by three time-delay, dual-element fuses, or three overload devices, are
subject to damaging overcurrents caused by primary single-phasing or secondary
single-phasing.

The worst case of single phasing occurs when system is star/delta or delta/star, in
this case the unbalance of voltages is quite more than when they are in delta/delta
or star/star.In the former case the motor current in one secondary phase increases
to 230 percent of normal current and this latter case the increase is also damaging
but is limited to 170 percent rather than the 230 percent value.

And as discussed before, when single phasing occurs the rate of increase of tem-
perature is more than the rate of increase of current in the lines. Hence due to
this reason the deterioration of the motor is more rapid than when overload or
overcurrent faults occur. Hence it is vital that the protection system is able to
isolate the power connections (in this case the relay drive module does the job) to
the motor from the supply in the nick of time and save the motor from going out
of business and maintain its stability and sustenance.

Methodology here is same as mentioned above. The only primary dierence in

the comparator logic is that we check for under voltage rather than over volt-
age. This is done by adjusting the RPS to give some threshhold voltage value as
reference voltage.

12
Overload

Figure 3.5: Block Diagram of Overcurrent fault detection

The components used here are:

 Comparator(LM324)
 Diodes
 Electrolytic capacitor
 Hall eect current sensor(ACS712)
 ESA MCB-51 microcontroller kit
 Step down transformer
 Regulated DC power supply
 Instrumentation amplier(AD620)
 Relay driver circuit

13
 Figure 3.6: Testing of current sensor ACS712

We performed a test on the existing hall current sensor before connecting it

to the protection module. The hall sensor gives a dc voltage oset value of 2.5V
for 0A current owing through it. We wanted to eliminate this oset value as we
wanted a pure AC voltage value for an AC current owing through the device. If
a pure AC voltage is converted to a pure DC voltage by the rectier and if there
is an oset, the comparator does not give a proper output as it cannot recognize
the input (having an oset) as valid. Hence with the use of AC coupling feature of
the digital oscilloscope, we were able to negate the oset and a pure AC wave was
visualized by the oscilloscope. In practice we used an instrumentation amplier IC
to realize the above function done by the AC coupling feature of the oscilloscope.

Figure 3.7: Output of ACS712 with DC oset

This graph was obtained without using the AC coupling feature of the digital
oscilloscope hence the oset of 2.5 V is clearly visible as we look at the graph. This
graph helped us to see the AC current wave as it went through the hall current
sensor. If we applied this current converted to voltage value to the rectier, the
rectier would not be able to decipher what is the AC component to be change to
DC because of the presence of the DC oset component and eventually due to this
problem the comparator would not sense the signal as it needs a proper DC input
to recognize its inherent comparing logic (as we making it compare with a xed
14
DC reference voltage given by the DC regulated power supply component (RPS)).

Figure 3.8: Output of ACS712 with DC oset removed

Figure 3.9: Measured test data of ACS712 current sensor output

15
 This graph was obtained after using the AC coupling feature of the digital
oscilloscope hence the oset of 2.5 V is not visible as we look at the graph. The
coupling feature of the digital oscilloscope works on the principle of isolation of DC
components with the help of the coupling capacitor which only passes the AC part
and keeps out the DC part from casting its in uence on the circuit parameters.
In reality the logic of the coupling capacitor can only be obtained and works well
when the digital oscilloscope is put to use and it is very tough to make it work
without the digital oscilloscope and an alternative approach is needed. Hence we
are making the same thing(elimination of the DC oset part) happen by using the
instrumentation amplier.

For detecting the overload faults, we rst had to nd an appropriate method to

detect changes in the motor current. Hall sensor (ACS712) was used to detect the
current changes. It gives a DC voltage value for DC currents and an AC voltage
value for AC currents. There was a problem when we attempted to sense the AC
motor current, The sensor only took account of the average value of the motor
current and also gave a DC oset (for this particular sensor ACS712- has an oset
value of 2.5V for 0A condition) value with the AC current sensed voltage value.
Hence this approach did not give us the required results for fault detection and
elimination.

To eliminate the above diculty we added an instrumentation amplier to e-

liminate the oset. As the output of the instrumentation amplier takes into
dierential input and the gain can be amplied to an appropriate value by chang-
ing the value of the dierential resistance. By giving an input of 2.5V as reference
voltage, the oset of 2.5V can be easily eliminated.

Figure 3.10: Pin diagram of AD620 Instrumentation amplier

16
 AD620 is an 8 pin IC. AD620 is well suited for multiplexed applications with
its settling time of 15 s to 0.01 percent, and its cost is low enough to enable designs
with one in-amp per channel.
AD620 has a incredibly high accuracy of 40 ppm with maximum nonlinearity, low
oset voltage of 50 V max, and oset drift of 0.6 V/C max, is ideal for use in
precision data acquisition systems, such as weigh scales and transducer interfaces
hence has also been used in designing systems where such precision techniques
(like protection systems for motors as done here ) are required to detect changes
and act upon it.
This device was used by us to eliminate the DC voltage oset given by the hall
current sensor. The elimination is based on the input taken by this IC. The input
of the instrumentation amplier is proportional to the dierence between the Vin
and Vref given to the IC and this can amplied to any value by varying the resis-
tance value which is connected between pins 1 and 8.

Gain = Vo / (V2-V1) = ( 1+ (2R1/Ri)) x (R3 / R2)

Where Vo = output voltage
V2 = input voltage
V1= reference voltage (for this case it is 2.5V to eliminate the DC oset)
Ri = variable resistance set to change gain value to any suitable value.
R1,R3,R2 = these resistance values are already set by the makers of the devices
and the gain value is independent of these values and only depends on Ri value.
The output of the instrumentation amplier is given to the bridge rectier module
which converts the AC to suitable DC value and this voltage is ltered using a
capacitor lter and nally given to the comparator block which gives a one or
a zero as a digital output to the microcontroller block depending on normal or
overcurrent (overload) condition.

3.5.2 Software Implementation

Overvoltage Algorithm:

Step1: Start

Step2: Initialize the comparators by giving input and reference voltages.

Step3: Each comparator produces 1 bit output which is given to microcon-

troller.

Step4:One Input port is checked for high condition.

Step5: Low input depicts Normal condition.

Step6: High input depicts faulty condition.

Step7: Any output port of microcontroller can be connected to the relay.

Step8:In case of fault, output port becomes high and it trips the relay thus,
disconnecting the motor from supply.

17
 Undervoltage Algorithm:

Step1: Start

Step2: Initialize the comparators by giving input and reference voltages.

Step3: Each comparator produces 1 bit output which is given to microcon-

troller.

Step4:One Input port is checked for low condition.

Step5: High input depicts Normal condition.

Step6: Low input depicts faulty condition.

Step7: Any output port of microcontroller can be connected to the relay.

Step8:In case of fault, output port becomes high and it trips the relay thus,
disconnecting the motor from supply.

Overcurrent Algorithm:

Step1: Start

Step2: Initialize the comparators by giving input and reference voltages.

Step3: Each comparator produces 1 bit output which is given to microcon-

troller.

Step4:One Input port is checked for high condition.

Step5: Low input depicts Normal condition.

Step6: High input depicts faulty condition.

Step7: Any output port of microcontroller can be connected to the relay.

Step8:In case of fault, output port becomes high and it trips the relay thus,
disconnecting the motor from supply.

18
 Single-Phasing Algorithm:

Step1: Start

Step2: Initialize the comparators by giving input and reference voltages.

Step3: Each comparator produces 1 bit output which is given to microcon-

troller.

Step4:Each three lines of Input port is checked for low condition.

Step5: High input in all three lines depicts Normal condition.

Step6: Low input in any one line depicts faulty condition.

Step7: Any output port of microcontroller can be connected to the relay.

Step8:In case of fault, output port becomes high and it trips the relay thus,
disconnecting the motor from supply.

Figure 3.11: Experimental Setup

19
3.6 Summary

In the chapter we discussed the detailed methodology adopted by us to achieve

the desired outcomes in the protection of induction motor design system. All
the components used in the process were also mentioned with the detailed usage
of each individual component.The detailed hardware implementation process was
also discussed and the algorithm for software implementation was also apprised in
this chapter.

20
Chapter 4

RESULT ANALYSIS

4.1 Introduction

Here we will showcase the various results obtained by us in the experimentation

process by inducing the various precursor faulty conditions within the system and
observing the behaviour of the microcontroller and relay system in protecting
the motor/system whenever these faulty conditions occur. This section consists
the tabulated columns of the various values we used to test the various faulty
conditions.

4.2 Result Analysis

Figure 4.1: Display for normal condition testing

Table 4.1: Normal Condition testing details

Input(V) Reference(V) Output(V) Display

8 9 67mV(Low) "Normal"

21
 Figure 4.2: Display for Overvoltage testing
Table 4.2: Overvoltage testing details

Input(V) Reference(V) Output(V) Display

9.3 9 11.16 V(high) "Overvoltage"

If the voltage is increased to more than its rated value (here the rated voltage set
by us is 420V) then the overvoltage problem is detected and the microcontroller
LCD starts to display the above message and the relay driver module trips the
supply to the motor causing the motor to stop.

22
 Table 4.3: Single-Phasing testing details

Input(V) Reference(V) Output(V) Display

0(in any one line) 8 67mV(Low) "Single-Phasing"

Figure 4.3: Display for Single phasing testing

We removed the E3 phase of the 3-phase autotransformer to make single

phasing scenario a reality in the motor. The reason we removed the E3 phase and
not the R-phase of the supply directly is an important one.

The RYB sequence of the supply is connected in star and the autotransformer
is connected in delta and the motor is also connected in delta.

Now as previously mentioned the single phasing more adversely aects those sys-
tems which are either connected in start/delta or delta/star rather than those
connected in star/star or delta/delta as current in the former increases to 230
percent of rated current while in the latter the current increases to 170 percent
which is also damaging but relatively it is lesser than the former. This above is
not the only problem, there is also a lot of voltage unbalance which could occur
if we remove the R-phase of the supply directly rather than opening any phase of
the 3-phase autotransformer to induce single phasing condition in the motor.

23
 Table 4.4: Undervoltage testing details

Input(V) Reference(V) Output(V) Display

7.6 8 67mV(Low) "Undervoltage"

Figure 4.4: Display for Undervoltage testing

If the voltage is reduced to less than its running condition value ie 400V
(here the threshold value of voltage for this condition set by us is 370V) then the
undervoltage problem is detected and the microcontroller LCD starts to display
the above message and the relay driver module trips the supply to the motor
causing the motor to stop.

24
 Table 4.5: Overcurrent testing details

Input(A) Input(V) Reference(V) Output(V) Display

4 7.4 7 11.16 V(High) "Overcurrent"

Figure 4.5: Display for Overcurrent testing

If the load is increased to more than its rated value (here the rated current
of the 3-phase induction motor is 3.3A) then the overcurrent problem is detected
and the microcontroller LCD starts to display the above message and the relay
driver module trips the supply to the motor causing the motor to stop.

25
Chapter 5

CONCLUSION AND FUTURE WORK

Protection of three phase induction motor from undervoltage, single phasing, over
current and overvoltage ensures smooth running of the 3- phase induction motor
and improves its lifetime and its eciency. Generally theses faults come about
when we violate with the limits of the motor (exceed its ratings). We also during
the time we spent working on the project learnt a lot of theoretical concepts re-
garding motors in general and AC motors in particular.

We learnt how adversely these faults aect the functioning of the motor. Learnt
more about single phasing which is a very common type of fault occurring with-
in induction motors and learnt how badly it eects the motor when connected in
dierent type of orientations (namely star/star,delta/delta or star/delta,delt/star).

We also managed to use and test a lot of electrical and electronic components
during the various phases of our project work. For overall functioning we used a
ESA MCB-51 microcontroller, which was the main control unit and operated the
relays. which eventually tripped the connection to the motor whenever any fault
occurred.

For current sensing,we initially used a current transformer to test out conditions
but we eventually went with the hall current sensor(ACS712) as gives a much more
stable and suitable output to the comparator block. We also got to use and learn
about the instrumentation amplier(AD620) and we got to this result after a lot
of testing to nd a solution for removing the DC oset given by the current sensor.
The instrumentation amplier helped us to eliminate the DC oset as its input
is proportional to the dierence of voltages (Vin and Vref) and with a help of a
variable resistance we can vary the gain to get a suitable output.

For future this type of a protection system will be useful to all small scale in-
dustries as it is way cheaper than protection systems designed with the help of
PLCs and also this protection system is able to visualize and analyze the current
and voltage parameters which cannot be done by the latter.

26
Chapter 6

BIBLIOGRAPHY

1. Kersting W.H., "Causes and eects of single-phasing induction motors,"

IEEE Transactions on Industry Applications, Vol. 41, no. 6, pp. 1499-1505,
Dec. 2005.
2. Javed A. and Izhar T., "An improved method for the detection of phase
failure faults in poly phase Induction machines," Third International Con-
ference on Electrical Engineering, 2009, ICEE '09, pp. 1-6, 9-11 April 2009,
Lahore.
3. Sudha M. and Anbalgan P., "A Novel Protecting Method for Induction Motor
Against Faults Due to Voltage Unbalance and Single Phasing," 33rd Annual
Conference of the IEEE on Industrial Electronics Society, 2007, pp. 1144-
1148, 5-8 Nov. 2007, Taipei.
4. Cunkas M., Akkaya R. and Ozturk A., "Protection of AC motors by means of
microcontrollers," 10th Mediterranean Electrotechnical Conference, MELE-
CON 200., Vol.3, pp. 1093-1096 vol. 3, May 2000
5. Bayindir R., Sefa I, Colak I. and Bektas A., "Fault Detection and Protection
of Induction Motors Using Sensors," IEEE Transactions on Energy Conver-
sion, Vol. 23, no.3, pp.734-741, Sept. 2008
ANNEXURES
 ANNEXURE A

Figure 6.1: Flowchart for Overvoltage sensing

Figure 6.2: Flowchart for Undervoltage sensing
Figure 6.3: Flowchart for Overcurrent sensing
Figure 6.4: Flowchart for Single Phasing sensing
 ANNEXURE B

Table 6.1: Bill of materials

Material Quantity Total Cost(Rs) Purchased/Issued (P/I)

Step down Transformer 3 450 P
Hall sensor 1 280 P
Rectier Diodes 8 16 P
Capacitor 3 6 P
IC LM324 2 40 P
Relay driver 3 270 P
ESA MCB-51 1 - I
Autotransformer 1 - I
DC Power supply 3 - I
Multimeter 1 - I
3 phase Motor 1 - I
IC AD620 1 450 P
 Project Details
Student Details:

Student Name: Rohan Prakash

Register Number: 130906562 Section / Roll No Section:C; 39
Email Address : prakashrohan1995@gmail.com Phone No (M): 9844311967
Student Signature:

Student Name: Raunak

Register Number: 130906572 Section / Roll No Section:C; 41
Email Address : raunak.kashyap1993@gmail.com Phone No (M): 7259604810
Student Signature:

Project Details:

Project Title: Protection of Three-Phase Induction Motor

Project Duration 4 months Project Start Date Jan 9 2017
Organization Details:

Organization Name: Manipal Institute of Technology, Manipal

Dept. of Electrical & Electronics Engg,

Full postal address : MIT Manipal, Manipal 576 104,
Karnataka State, INDIA
Guide Details:

Guide Name: Mr Ganesh Kudva

Dept. of Electrical & Electronics Engg,
Full postal address : MIT Manipal, Manipal 576 104,
Karnataka State, INDIA
Email address: ganesh.kudva@manipal.edu
Guide Signature: