Starting and Speed Control of 3-O Slip R

Starting & Speed control of 3-Ø slip ring IM motor
CHAPTER-1
INTRODUCTION
What happens if the motor is started as a normal induction motor?
If the slip ring induction motor is started with all the slip rings or the rotor terminals shorted, like a
normal induction motor, then it suffers extremely high locked rotor current, ranging up to 140%,
accompanied with very low locked rotor torque as low as 60%. So, it is not advised to start a slip ring
induction motor with its rotor terminals shorted.
So, there are different methods to control the starting current and speed of 3-ph Slip Ring Induction
Motor.
1) Frequency control method.
2) v/f control method.
3) Rotor emf injection method.
4) Rotor resistance control method.
In the 1st & 2nd methods stator side power electronic hardware is required. In case of rotor emf injection
method, generating AC voltage at slip frequency is a difficult task.
By using Rotor resistance control, Stator side hardware is not required. The disadvantages of the
first 3 methods can be overcome in the rotor resistance control method. At the time of normal running of
induction motor, for a constant torque load, Slip is proportional to rotor resistance. Therefore we can
also control the speed of the Induction motor for a given load.
This can be achieved using the ABB AC-31 Programmable logic controller. PLC is designed for
multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and
resistance to vibration and impact. PLC programs are typically written in a special application on a
personal computer, and then downloaded by a direct-connection cable or over a network to the PLC. The
program is stored in the PLC either in battery-backed-up RAM or some other non-volatile flash memory.
So, using the outputs of the PLC we have designed a control panel in which we have used the contactors
to give the supply to the motor and relays to short or cut the resistance from the rotor.
1 Department of Electrical & Electronics Engg.,

CHAPTER-2
3-PHASE SLIP RING INDUCTION MOTOR
An induction motor or asynchronous motor is a 3 phase 4 pole induction motor. This is a type of
alternating current motor where power is supplied to the rotor by means of electromagnetic induction.
The 3 phase 4 pole induction motor electric motor turns because of magnetic force is exert between the
stationary electromagnet called the stator and a rotating. This 3 phase 4 pole inductions electric motor
turns because of magnetic force exert between a motionless electromagnet called the stator and a rotating
electromagnet called the rotor.
2.1 Construction of slip-ring induction motor:
Fig.2.1
Stator:
The stator consists of 3-ph winding forms wound 'poles' that carry the supply current to induce a
magnetic field that penetrates the rotor. In a very simple motor, there would be a single projecting piece
of the stator (a salient pole) for each pole, with windings around it; in fact, to optimize the distribution of
the magnetic field, the windings are distributed in many slots located around the stator, but the magnetic
field still has the same number of north-south alternations. The number of 'poles' can vary between
motor types but the poles are always in pairs (i.e. 2, 4, 6, etc.).

Slip ring rotor:

The slip ring induction motors usually have “Phase-Wound” rotor. This type of rotor is provided
with a 3-phase, double-layer, distributed winding consisting of coils used in alternators. The rotor core is
made up of steel laminations which has slots to accommodate formed 3-single phase windings. These
windings are placed 120 degrees electrically apart.
Fig.2.2
The rotor is wound for as many poles as the number of poles in the stator and is always 3-phase,
even though the stator is wound for 2-phase.
These three windings are “starred” internally and other end of these three windings are brought
out and connected to three insulated slip-rings mounted on the rotor shaft itself. The three terminal ends
touch these three slip rings with the help of carbon brushes which are held against the rings with the help
of spring assembly.
These three carbon brushes are further connected externally to a 3-phase star connected rheostat.
Thus these slip ring and external rheostat makes the slip ring induction motors possible to add external
resistance to the rotor circuit, thus enabling them to have a higher resistance during starting and thus
higher starting torque.
2.2 Equivalent circuit of slip-ring induction motor:
To understand the behavior of an induction motor when the rotational speed and supply
frequency varies, it is helpful to look at the equivalent circuit. The equivalent circuit shows an
electrically equivalent circuit to the motor's construction, where the two left most terminals would be
connected to a power supply.

Fig.2.3
On the left side of the circuit, the equivalent resistance of the stator, which consists of the copper
resistance and core resistance in series, is shown as Rs.
During asynchronous operation, the stator also induces some reactance, which is represented by the
inductor Xs. The next inductor Xr represents the effect of the rotor passing through the stator's magnetic
field.
The effective resistance of the rotor (again with rotating in a magnetic field), Rr, is composed of:
 The equivalent value of the machine's real power (which changes with the torque and the load on
the machine)
 The ohmic resistance of the stator windings and the squirrel cage of shorted rotor windings.
At idle, the induction motor equivalent circuit is essentially just Rs and Xs, which is why this machine
only takes up mostly reactive power. The idle current draw is often near the rated current, due to the
copper and core losses which exist even at no load. In these conditions, this is usually more than half the
power loss at rated load. If the torque against the motor spindle is increased, the active current increases
by Rr, and thus in the rotor. Due to the construction of the induction motor, the two resistances both
induce a magnetic field, in contrast to the three-phase synchronous machine, where the magnetic flux is
induced only by the reactive current in the stator windings.
The current produces a voltage drop in the cage portion of the Rr, but only a slightly higher voltage
drop in the stator windings. Consequently, the losses increase with increasing load in the rotor faster than
they do in the stator. The copper resistance Rs and the "copper" resistance from the cage portion of Rr
both cause I2R losses, and therefore the efficiency of the machine improves with increasing load. The
efficiency of the machine reduces with temperature. In contrast with a smaller frequency of the reactance
Xs also getting smaller. In compliance with the rated current must shrink by the drive voltage delivered.

Thus, the ratio of the voltage divider Rs to Xs and Rs and this increases engine power losses. In
continuous operation this can only be an approximation because a nominal torque is generated because
the cooling of rotor and stator is not included in the calculation. At higher than the rated speed or rated
frequency induction motor can, however - in the context of isolation – are working on higher voltages
and is more effective.
Frequently today, Rs / Rr are measure automatically and are thus in a position for any motor
connected to automatically configure itself and thus to be protected from overload.
A holding torque or speed close to zero can be achieved with a vector control. Here, too though,
there can be problems with cooling since the fan is usually mounted on the rotor.
2.3 Principle of operation:
The principle of operation of the induction machine is based on the generation of a rotating
magnetic field.
Production of Rotating Magnetic Field:

A symmetric rotating magnetic field can be produced with as few as three coils. The three coils
will have to be driven by a symmetric 3-phase AC sine current system, thus each phase will be shifted
120 ˚ in phase from the others. For the purpose of this example, the magnetic field is taken to be the
linear function of the coil's current.
Since the flux is proportional to magnetizing current drawn by the three phase winding three
magnetic fluxes occurs as shown in the fig.
Mathematically:
Let us consider waveforms as
Fig.2.4

As shown in figure3.4 angle of the resultant flux varies linearly and magnitude of the resultant flux will
be maintained constant, therefore produces the rotating magnetic field.
Fig.3.5
The above figure 2.5 shows the direction of the three phase flux at various instants.
The induction motor does not have any permanent magnets on the rotor; instead, a current is
induced in the rotor. To achieve this, stator windings are arranged around the rotor so that when
energized with a poly-phase supply they create a rotating magnetic field pattern which sweeps past the
rotor. This changing magnetic field pattern induces current in the rotor conductors.
According to Lenz’s law these currents will induce in a direction such that it opposes the cause of
production of that currents, as a result magnetic field.
However, for these currents to be induced the speed of the physical rotor must be less than the
speed of the rotating magnetic field in the stator (the synchronous speed, Ns) or else the magnetic field
will not be moving relative to the rotor conductors and no currents will be induced. If by some chance
this happens, the rotor typically slows slightly until a current is re-induced and then the rotor continues
as before. This difference between speed of the rotor and speed of rotating magnetic field in stator is
called slip. It is unit less & is the ratio between the relative speed of the magnetic field as seen by the

rotor (the slip speed) to the speed of the rotating stator field. Due to this, an induction motor is
sometimes referred to as an asynchronous machine
Synchronous speed:
The Synchronous speed of the Induction motor is the speed at which stator rotating magnetic
field rotates in the air gap of the machine.
It can be shown that the synchronous speed of a motor is determined by the following formula:
120
=
Where,
Ns is the synchronous speed of the machine,
f is the frequency of the AC supply,
p is the number of magnetic poles per phase.
In this Project, a 4-pole motor operating on 50Hz power would have a speed of:
120 ∗ 50
= = 1500
4
Slip:
Fig.3.6
Fig.2.6 represents the typical torque curve as a function of slip

The slip is defined as a ratio of relative to the synchronous speed and is calculated using:
=
Where,
s is the slip, usually between 0 and 1
Nr is rotor rotation speed in rpm
Ns is synchronous speed in rpm
2.4 Rotor resistance in slip-ring induction motor:
A wound rotor induction motor has a stator like the squirrel cage induction motor, but a rotor
with insulated windings brought out via slip rings and brushes. However, no power is applied to the slip
rings. Their sole purpose is to allow resistance to be placed in series with the rotor windings while
starting. This resistance is shorted out once the motor is started to make the rotor look electrically like
the squirrel cage counterpart.
Fig.2.7
Fig.2.8

Why put resistance in series with the rotor?
Slip ring induction motors draw 50% to over 100% of full load current (FLC) during starting. While this
is not a severe problem for small motors, it is for large (10's of kW) motors. Placing resistance in series with the
rotor windings not only decreases start current, but also increases the starting torque. Figure below shows that by
increasing the rotor resistance from R0 to R1 to R2, the breakdown torque peak is shifted left to zero speed. Note
that this torque peak is much higher than the starting torque available with no rotor resistance (R0) slip is
proportional to rotor resistance, and pullout torque is proportional to slip. Thus, high torque is produced while
starting.
Fig.2.9
Fig.2.9 Breakdown torque peak is shifted to zero speed by increasing rotor resistance.
The resistance decreases the torque available at full running speed. But that resistance is shorted
out by the time the rotor is started. A shorted rotor operates like a squirrel cage rotor. Heat generated
during starting is mostly dissipated external to the motor in the starting resistance. The complication and
maintenance associated with brushes and slip rings is a disadvantage of the wound rotor as compared to
the simple squirrel cage rotor.
This motor is suited for starting high inertial loads. A high starting resistance makes the high pull
out torque available at zero speed. For comparison, a squirrel cage rotor only exhibits pull out (peak)
torque at 80% of its' synchronous speed
In this project we are going to introduce the rotor circuit external resistance up to three ohms, and
these resistances can be cut down in three steps, so that we can achieve three different speeds.

2.5 STARTING AND SPEED CONTROL OF 3-PHASE SLIP-RING INDUCTION MOTOR
2.5.1 Starting methods:
Normally in any electrical machine whenever the electrical supply given the EMF will be
induced in the machine which opposes the main supply. In rotating machines like induction motor or DC
motor this induced emf is called Back EMF.
The Back EMF induced in the Induction motor or any rotating machine is directly proportional to
the speed of the motor at which it is running. At the time of starting, since the motor is at rest, the Back
EMF is Zero. Therefore there will not be any opposition to the main supply. As a result huge amount of
current will be drawn by the motor.
Therefore, 3-phase induction motors employ a starting method not to provide a starting torque at
the rotor, but because of the following reasons;
1) Reduce heavy starting currents and prevent motor from overheating.
2) Provide overload and no-voltage protection.
There are many methods in use to start 3-phase induction motors. Some of the common methods are;
 Direct on-line starter.
 Star-Delta starter.
 Series Reactance method.
 Variable frequency drive.
 Rotor Resistance method of starting.

 Direct On-Line (DOL) starting:
Direct online starting also known as across the line starting and full voltage starting, involves
connecting each terminal of a three-phase induction motor to a separate line of a device. In this
arrangement, the motor current is the same as the line current and the terminal voltage of the induction
motor equals the line voltage. A disadvantage of the direct online starting method is that the stator draws
a high current that can damage the windings of the three-phase induction motor. The direct online
starting method can also cause a voltage drop or fluctuation that can affect devices along the line.
The DOL starter attracts high current. Therefore, it may be inconvenient to the other users of the supply
line since whenever a motor with a DOL starter is turned on, they will experience a voltage drop.
DOL starter also provides a very high starting torque. This can be a strain on the driven load. The high
starting torque may cause mechanical wear on the components connected to the load. Because of these
reasons, the DOL starter can be used for only low power or more specifically stated, motors with a rating
of less than 5kW.
 Star-Delta starting:
In a star connection, the windings of the induction motor connect from the supply phases to the
neutral. In a delta or mesh connection, the windings connect between the supply phases. A star
connection creates higher voltage to the windings of the three-phase induction motor than a delta
connection. A starter with the ability to utilize both star and delta connections, also known as a star start
delta run connection, initializes the three-phase motor using a star connection then transfers to a delta
connection when the motor reaches a set speed. A disadvantage of the star delta connection is the
reduction in voltage and the low starting torque that can have an adverse effect on devices or pumps that
have a high breakaway torque. A star-delta connection is more complex than a direct online connection
because it utilizes a speed switch and timers.
The induction motor requires a shock to start and another shock when the star-delta connection transfers
from star to delta. The star-delta method is often convenient for partial acceleration.
The star-delta starting method achieves low starting current by first connecting the stator windings in
star configuration, and then after the motor reaches a certain speed, a double throw switch changes the
winding arrangements from star to delta configuration. This method provides slow starting torque which
can cause the motor to stall.

 Series reactor connection:
A reactor in series with the terminals of the motor decreases the terminal voltage of the induction
motor, decreasing the initial current. The impedance decreases as the induction motor accelerates until a
bypass method makes the motor run at full speed and full voltage.
 Variable frequency drive:
A variable-frequency drive starts a three-phase induction motor at a frequency low enough to

initialize a full-rated torque without an inrush of current. The low frequency increases the torque because
it increases the impedance of the rotor circuit with slip frequency.
 Rotor resistance starting:
This method allows external resistances to be connected to the rotor through slip rings and
brushes. Initially, the rotor resistance is set to maximum and is then gradually decreased as the motor
speed increases, until the resistance becomes zero.
The rotor resistance starting mechanism is usually very simple when compared with other
methods. It also has no maintenance costs. A considerable amount of heat is generated through the
resistors when current runs through them. However, the rotor impedance method is known to be the
smoothest and least stressful method of accelerating an induction motor. The mail advantage is that it
allows the motor to be started while the motor is on load
2.5.2 SPEED CONTROL METHODS:
Unlike D.C. Motors, A.C. Induction Motors are not suitable for variable speeds. Their speed
control and regulation is comparatively difficult when compared with D.C. Motors. These are some of
the methods which are commonly used for the speed control of squirrel cage induction motors:
1. Changing applied voltage.
2. Changing applied frequency.
3. Changing number of stator poles.
4. Changing the rotor circuit resistance.

Of the above four methods, first three can be used for both squirrel cage and slip ring induction motors,
where as forth method is only applicable for slip ring induction motor.
 Changing applied voltage:

As we know the electromagnetic torque developed by the motor is given by the equation is
( )= .
+( )
Where,
S = Slip of the motor,
E2= Rotor induced EMF at standstill condition,
R2= Rotor resistance,
X2 = Rotor winding reactance at standstill condition
At normal working conditions the Slip of the induction motor is very low and for constant torque load,
Therefore equation can be written as
( )=
Therefore, =
Since the Rotor induced EMF is directly proportional to the applied voltage to the Stator,
=
−
Since the synchronous speed ( ) is constant, by changing the applied voltage ‘V’, it is possible to vary
the Rotor running speed ( ).
This method, even though easiest, it is rarely used. The reasons are
(a) For a small change in speed, there must be a large variation in voltage.
(b) This large change in voltage will result in large change in flux density, thereby seriously
disturbing the magnetic distribution/condition of the motor.
(c) This method also requires a large power electronic circuit (AC voltage controller).
As the Slip is inversely proportional to the square of the voltage, to increase the speed above
synchronous speed, voltage has to be increased more than the rated, therefore ‘v/f’ ratio greatly
increases, Thereby the flux density increases and causes some abnormal conditions.

 Changing applied frequency:
We all know that the synchronous speed of the induction motor is given by
120
=
So from this relation, it is evident that the synchronous speed and thus the speed of the induction
motor can by varied by the supply frequency.
Limitations of these methods are:
(a) The motor speed can be reduced by reducing the frequency, if the induction motor happens to be
the only load on the generators.
(b) If supply is taken from the GRID, It requires a cyclo converter circuits at the stator side which is
very complex.
Even then the range over which the speed can be varied is very less. This method is famous in some
electrically driven ships although not common in shore.
 ‘v/f’ control:
Fig.2.10 Characteristics of ‘v/f’ control
For the speeds below rated speed for large variation of voltage, small change in speed occurs. Therefore
normally ‘v/f’ control is used. In this method, voltage and frequency are varied with respect to each other, so that
the ratio is maintained constant. Therefore the flux density will be maintained constant. This method combines the
advantages of both above two methods. But this method requires A Converter- Inverter circuit at the stator side.

 Changing the number of stator poles:

As we know the relation between the synchronous speed and the number of poles,
120
=
So the number of poles is inversely proportional to the speed of the motor. This change of number of
poles can be achieved by having two or more entirely independent stator windings in the same slots. Each winding
gives a different number of poles and hence different synchronous speed.
Since the Induction motors are normally designed for a specific number of poles, by changing the number
of poles it works with less efficiency. And by using this method only two sets of speeds can be achieved.
 Changing the rotor resistance:

As we discussed in the voltage control session
( )=
For a constant torque and constant applied voltage, the slip to rotor resistance ratio is constant. Therefore
=
By increasing the rotor resistance, it is possible to increase the slip; thereby we can control the speed of
the induction motor.
This method of speed control of is also useful for starting of the induction motor. Since rotor is short
circuited, at the time of starting motor will draw large currents into the rotor. So to reduce the starting current this
method is used. This method not only reduces the starting current but also increases the starting current.
As we know the torque equation of induction motor is
( )= .
+( )
And the starting torque is,
( )= .
+
And the slip corresponding to maximum/Breakdown torque is
By considering all the above points Torque-slip or Torque speed characteristics are given as below.
R2>R1>R0

Fig.2.11 Torque-speed characteristics for different rotor resistances

CHAPTER-3
OVER LOAD PROTECTION
Thermal overload relays play a very important for protection of motors and generators both.
Thermal motor overload protection relays feature bi-metal strips jointly with a trip mechanism in a
casing made of insulating material. Whenever there is overload The motor current heats the bi-metal
strips, making them bend and activating the trip mechanism after a particular interval which is based on
the current- setting. The release mechanism actuates an auxiliary switch that breaks the motor contactor's
coil circuit as shown in circuit diagrams below. A changing position indicator signals the condition
"tripped".
Fig3.1

3.1 Working Of An Thermal Over Load Relay
Principle of operation of a three terminal delayed bimetal motor protection relay with
temperature compensation.
Fig 3.2
Fig 3.2 shows the circuit of overload relay , various components are discussed below:-
A = Heated bimetal strips
B = Trip slide
C = Trip lever
D = Contact lever
E = Reparation bimetal strip
The bimetal strips may be warmed directly or indirectly. In the first case, the current flows
directly through the bimetal, in the second through an insulated heating. The insulating material causes
some delay of the heat flow so that the inertia of thermal relays that are heated is greater than with their
right heated counterparts. Often both principles are joined. For motor rated currents over approx. 100 A,
the motor current is conducted via current transformers. The current transformer's secondary current
subsequently heats the thermal overload relay. This means that the dissipated power is reduced and, on
the other, that the short-circuit withstand ability is raised. The tripping current of bimetal relays can be
set on a current scale - by displacement of the trip mechanism relative - so that the protection
characteristic can be matched to the secure item in the key area of continuous responsibility.

CHAPTER- 4
4.1 PROGRAMMABLE LOGIC CONTROLLER
A PROGRAMMABLE LOGIC CONTROLLER (PLC) is a digital computer used for automation

of electromechanical processes.
Before the PLC, control sequencing, and safety interlock logic for manufacturing automobiles
was accomplished using hundreds or thousands of relays, cam timers and drum sequencers and dedicated
closed-loop controllers.
Early PLCs were designed to replace relay logic systems. These PLCs were programmed in
“ladder logic”, which strongly resembles a schematic diagram of relay logic.
The computer is connected to the PLC through Ethernet, RS-232, RS-485 or RS-422cabling.
A small PLC will have a fixed number of connections built in for inputs and outputs. Typically,
expansions are available if the base model has insufficient I/O.
PLC programs are typically written in a special application on a personal computer, and then
downloaded by a direct-connection cable or over a network to the PLC. The program is stored in the
PLC either in battery-backed-up RAM or some other non-volatile flash memory.
Unlike general-purpose computers, the PLC is designed for multiple inputs and output
arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and
impact.
The PLC’s have many applications in the day to day life. They are easily programmable and they
can be operated using the cables, modems etc. All the automation processes are been done but using the
PLC’s, as they are more reliable.

4.11 BLOCK DIAGRAM OF PLC:
Fig 4.1
The central unit, with a local inputs / outputs extensions interface and a CS 31 bus interface a
SRAM memory where the user program and data is loaded.
A flash EPROM memory which contains: a backup of the user program with the program
constants, the user program is a set of universal functions conceived to cover all applications.
After being translated into instructions understandable by the central unit it is loaded in
RUN or STOP mode into the SRAM and then saved from the SRAM to the Flash EPROM.
Thereby, at each program launch the user program, saved in the Flash EPROM, is copied to the
SRAM for processing by the microprocessor.

4.12 ABB AC-31 50 Series PLC:
Fig.4.2
This is the central unit of the ABB AC 31 Programmable Logic Controller.
The AC 31 brings accessibility to automation users alike, for any application with 14 to 1000
inputs / outputs and more, using the same set of basic components.
Extensible central unit with CS31 bus with 8 isolated inputs 24 V DC & 6 incorporated relay outputs 250
V AC / 2 A, RS232 or RS485 interface for programming or ASCII or MODBUS communication , 24 V
DC power supply
Each central unit incorporates a specific number of binary inputs / outputs and occasionally
analog. It is possible, depending on the central unit, to increase the number of inputs / outputs, to add
input / output extensions connected directly to the central units or remote input / output units via the
CS31 twisted pair. The 50 series central unit, with a local inputs / outputs extensions interface and a
CS31 bus interface. In the 50 series it’s possible to increase the number of inputs / outputs of the basic
central unit by adding remote units.
The central unit controlling the system is called the MASTER central unit. The maximum bus
length is 500 m without an amplifier and 2000 m with 3 amplifiers (1 NCB or NCBR unit enables bus
amplification for 500 m).
The master central unit can manage up to 31 connection points called SLAVES, such as:

A remote unit with extension possibilities: a maximum of 6 extension units comprising of a maximum of
8 analog input channels and 8 analog output channels. A simple remote unit (without extension) with
analog or binary inputs / outputs
The maximum number of remote ANALOG units depends on the MASTER central unit:
50 series:
 A maximum of 31 remote analog input units
 A maximum of 31 remote analog output units
 A maximum of 15 extensible remote units (ICMK14F1) with analog input / output extensions +
1 remote analog input / output unit (15 x 2 + 1 = 31)
 A mixed binary / analog configuration within the previous limits.
The 50 series central unit memory is composed of two distinct areas:
 A SRAM memory where the user program and data is loaded.
 A Flash EPROM memory
A Flash EPROM memory which contains a backup of the user program with the program constants,
the configuration data, and the system program protected against access from the user program. An
incorporated battery, which is available only in the 50 series, also enables the backup of internal
variables.
The user program is a set of universal functions conceived by the constructor to cover all applications
and ensure all the basic PLC functions. It is developed with the AC31GRAF software. After being
translated into instructions understandable by the central unit it is loaded in RUN or STOP mode into the
SRAM and then saved from the SRAM to the Flash EPROM. Thereby, at each program launch the user
program, saved in the Flash EPROM, is copied to the SRAM for processing by the microprocessor.

4.13 Addressing the inputs and outputs:
Fig.4.3
The central unit is automatically addressed as 62; the remaining extensions will be 63, 64, and
soon.
The binary INPUTS of the central unit are addressed as %I62.00, %I62.01, %I62.02......%I62.07,
The binary OUTPUTS are given as %O62.00, %O62.01, %O62.02......%O62.05.
In case of analog inputs it is %IW62.00, %IW62.01 %IW62.07 and analog outputs are given as
%OW62.00, %OW62.01....%OW62.05.

4.2 PROGRAMMING OF PLC & COMMUNICATION WITH PLC
The AC31GRAF software is used with all of the AC 31 central units. This software runs under
windows (3.1, NT or 95). 12 Megabytes of free disk space are required for the installation. Execute the
setup.exe for an automatic installation.
The software allows you to create, send, test, recover and print user programs as well as
initializing, starting and stopping the central unit.
4.21 Different programming languages:
 Ladder Diagram & Quick Ladder Diagram
 Functional Block Diagrams
 Sequential Flow Chart
 Instruction List
4.21.1 LADDER DIAGRAM &QUICK LADDER DIAGRAM Languages:
Ladder Diagram (LD) is a graphic representation of Boolean equations, combining contacts

(input arguments) with coils (output results). The LD language enables the description of tests and
modifications of Boolean data by placing graphic symbols into the program chart. Using the quick LD
editor, you connect function boxes to Boolean lines.

Fig 4.4 Example of Ladder Diagram
4.21.2 FUNCTIONAL BLOCK DIAGRAM Language:
FBD diagram describes a function between input variables and output variables. A function is
described as a set of elementary function blocks. An entire function operated by an FBD programs built
with standard elementary function blocks from the AC31GRAF library.
Fig.4.5 Example of Functional Block

4.21.3 SEQUENTIAL FUNCTION CHART Language:
Fig.4.6
Sequential Function Chart (SFC) is a graphic language used to describe sequential operations.
The process is represented as a set of well defined steps, linked by transitions.
The basic graphic rules of the SFC are:
 A step cannot be followed by another step
 A transition cannot be followed by another transition.

Fig.4.7 Example of SFC
4.21.4 INSTRUCTION LIST Language:
IL is a low level language. It is highly effective for smaller applications or for optimizing parts of
an application.
Example:-
Start: LD BUTTON1 (* push button *)

ANDN%I62.02 (* command is not forbidden *)
ST START-MOTOR (* start motor *)

4.3 COMMUNTICATION WITH PLC:
Fig.4.8 Project manager
We use our personal computer to communicate with the device. A software which acts as an
interface between the user and the device .The software is required to be installed in the PC. An RS232
cable acts as in interface between PC and the PLC.
The AC31GRAF software allows you to create, send, test, recover and print user programs as
well as initializing, starting and stopping the central unit.
There will be a project manager in this software which provides programming as per the
requirement of the application of the user.
With the use of this project manager we can write the programs in different languages and store it
in the PLC. This project manager consists of many features, and has many predefined functional blocks
in it which can be used for the programming.

All the changes in the program can be done in the PC and then it can be transferred in to the PLC
by using an RS-232 cable. The PLC is very fast, and it responds immediately to any change in the
programs.
The AC-31 GRAF software provides a wide range of functions. We can divide the program into
different parts and write each part in different languages and then arrange them as per our requirement.
We can call the programs written in different projects.
Fig.4.9

CHAPTER-5
DESIGN OF THE PANEL BOARD & WORKING OF THE
PANEL, COMPONENTS USED IN THE PANEL
The PLC we have used is ABB AC-31, it takes DC 24volts input signals and gives out DC
24volts output signals. But here the aim is to start and run the three phase 415 volts slip ring Induction
motor. Therefore we need to use the relays and contactors to interface the Induction motor with PLC.
5.1 PANEL BOARD DESIGN:
Fig5.1
All the outputs of the PLC are brought on to the Panel Board.
This Panel is consisting of all the relays and contactors and main line supply terminals.
So, this panel board interfaces the three phase induction motor stator to the main line terminals.
And it also interfaces the short circuited terminals to the rotor resistance terminals. The circuit
diagram of the panel board is shown in figure 7.1.

5.2 PANEL BOARD CIRCUIT:
Fig 5.2

5.3 WORKING OF THE PANEL BOARD:

As per the program written in FBD language, first output signal comes on the terminal
%O62.00, this output will be given to contactor1 after the time delay of 10 seconds, then it closes its
three terminals, then R-Y-B phase sequence supply will goes to the induction motor stator terminals then
the motor starts running in forward direction. Then after 6 seconds of time delay the output signal comes
on the % O62.01 terminal and this output will be connected to TPDT relay1 in the panel board. As
TPDT relay1 shorts the first part of the resistance, speed of the induction motor will be gradually
increased. Then after 12 seconds the output comes on the terminal %O62.02, and this output will be
connected to TPDT relay2 on the panel board. As TPDT relay2 shorts the second part of the resistance,
speed of the induction motor will be gradually increased. Then after 18 seconds the output comes on the
terminal %O62.03, and this output will connected to TPDT relay3 shorts the third part of the rotor
resistance, then motor is having only its internal resistance so it reaches to its rated speed. Then after 20
seconds SPEED ENABLE switch is activated, by pressing it, we can use rotary switch to control speed
in 3 steps. As per the FBD program all the outputs will come to zero state, when STOP push button is
pressed. Therefore supply to the motor will be cut-off and three resistance circuits will be opened.
Fig 5.3
Then, when REVERSE push button is pressed, the output terminal %O62.04 is activated after time delay
of 10 seconds, as it is connected to the three phase supply in reverse phase sequence (B-Y-R). Reverse
phase sequence supply will be connected to the stator, so the motor starts running in reverse direction,
then after 6 seconds PLC gives the output on the terminal %O62.01 the corresponding relay that is
relay2 will cut-off the first part of the resistance, so the motor speed gradually increases, then after 12
seconds the output will come on the terminal %O62.02, then corresponding relay will cut-off the second
part resistance & the motor speed gradually increases, then after 18 seconds the output will come on the
terminal %O62.03, then corresponding relay will cut-down the total resistance then motor attains its
rated speed. Then after 20 seconds SPEED ENABLE switch is activated, by pressing it, we can use
rotary switch to control speed in 3 steps. As per the FBD program all the outputs will come to zero state,
when STOP push button is pressed. Therefore supply to the motor will be cut-off and three resistance
circuits will be opened.
5.4 COMPONENTS USED IN THE PANEL BOARD:
5.4.1 RELAYS
Relays are basically switches which operate with respect to electrical signals. Many relays use an
electromagnet to operate a switching mechanism mechanically, but other operating principles are also
used. Relays are used where it is necessary to control a circuit by a low-power signal (with complete
electrical isolation between control and controlled circuits), or where several circuits must be controlled
by one signal. Solid-state relays control power circuits with fixed contacts.
Fig 5.4

A simple electromagnetic relay consists of a coil of wire surrounding a soft iron core, an iron
yoke which provides a low reluctance path for magnetic flux, a movable iron armature, and one or more
sets of contacts. The armature is hinged to the yoke and mechanically linked to one or more sets of
moving contacts. It is held in place by a spring so that when the relay is de-energized there is an air gap
in the magnetic circuit. In this condition, one of the two sets of contacts in the relay pictured is closed,
and the other set is open. Other relays may have more or fewer sets of contacts depending on their
function.
Since the rotor three sets of resistors, to cut down the three resistors at a time in this project we
are using the relays which are having three NO’s. When the output comes from the PLC the relay will be
activated three NO’s will be closed at a time.
5.4.2 CONTACTORS:
When a relay is used to switch a large amount of electrical power through its contacts, it is
designated by a special name: contactor. Contactors typically have multiple contacts, and those contacts
are usually (but not always) normally-open, so that power to the load is shut off when the coil is de-
energized. Perhaps the most common industrial use for contactors is the control of electric motors.
Fig.5.51
The top three contacts switch the respective phases of the incoming 3-phase AC power, typically
at least 480 Volts for motors 1HP or greater. The lowest contact is an "auxiliary" contact which has a
current rating much lower than that of the large motor power contacts, but is actuated by the same
armature as the power contacts.

Fig 5.52
The auxiliary contact is often used in a relay logic circuit, or for some other part of the motor control
scheme, typically switching 230 Volt AC power instead of the motor voltage. One contactor may have
several auxiliary contacts, either normally-open or normally-closed, if required.
 Contactor is a large relay, usually used to switch current to an electric motor or other high-power
load.
 Large electric motors can be protected from over current damage through the use of overload
heaters and overload contacts. If the series-connected heaters get too hot from excessive current,
the normally-closed overload contact will open, de-energizing the contactor sending power to the
motor.
5.4.3 PUSH BUTTONS:
Fig.5.6
Push Button:- The push buttons are used to start or stop the motor. These buttons are connected to the
digital input of the PLC.

5.4.4 SELECTOR SWITCH:
Fig.5.7
Selector Switch:- The selector switch is interfaced with the PLC which is used to select the desired
speed of the induction motor.
5.4.5 ELECTRIC BULBS:

The electric bulbs are used resistors in the rotor circuit of the 3-phase sip ring induction motor.
The bulbs used here are the 200 watts electric bulbs.

5.5 PROGRAM USED IN THE PLC
We have written the program in the FUNCTIONAL BLOCK DIAGARM LANGUAGE. As we

have to use the timers in the program, we have chosen the FBD language so that we can’t make use of
the timer functions which are predefined in the library of the project manager. We had made use of the
T-ON and T-OFF functions and designed the program as per required time delay.
5.5.1 WORKING OF THE PROGRAM:
According to our program the motor will start with a delay of 2seconds after pushing the input
switch, as the motor starts exactly after 10seconds from the time of starting the 1st relay will closed and
the part of resistance gets shorted, after another 10seconds the 2nd relay will be closed and the total
external resistance will be cut off.
Then the motor runs with the rated speed for 15seconds and the motor comes to halt and the relay
gets opened. Exactly after 18seconds the contactor which has been given the reverse supply phase
sequence will get energized and the motor starts rotating in the anti clockwise direction, as in case of the
clockwise direction again the 1st relay will be shorted after 10seconds and after another 10seconds the
other relay will also gets shorted, and the total resistance is cut off, the motor rotates with rated speed in
the anti clock wise direction for 15seconds and turns off.
5.5.2 FUNCTIONS USED IN THE PROGRAM:

We have used a binary function (OR) and 2 timer functions (T-ON AND T-OFF).
5.5.21 BINARY FUNCTION (OR):
Fig. 5.9
PARAMETERS:
E1 BINARY %I, %M, %O, %S, %K Operand 1

E2 BINARY %I, %M, %O, %S, %K Operand 2

A1 BINARY %M, %O, %S Result of the OR combination
DESCRIPTION:
This connection element realizes a logical OR combination of the operands at the inputs. The result is
allocated to the operand at the output.
Truth table:
5.5.22 TIMER FUNCTIONS:
T-ON DELAY:
Fig.5.10.1
PARAMETERS:

DESCRIPTION:-
The 0-1 edge of the input IN is delayed by the time PT at the output Q. The output Q retains 0 level if
the input IN returns to 0 level before the time PT has elapsed. The time elapsed can be consulted at the
output ET and the preset time value at the Input PT can be modified when the timer is running. The
preset time is specified in milliseconds. The time range which can be specified is: 1 m ... 24.8 days.
Maximum time offset at the output : < 1 cycle time

Meaningful range for PT: > 1 cycle time
Fig.5.10.2
Note:
If the time is less than 65s, a word can be used for the preset time PT. Then the PT
Input can be used:
 With all the other word functions

 From the central unit potentiometer
 For MODBUS communication (double word are not allowed in MODBUS) directly without
double word to word conversion.
Started timers are processed by the PLC operating system and are therefore completely independent of
processing of the PLC program. An appropriate message of the operating system is not issued to the
affiliated timer block in the PLC program until the timer has elapsed.
Processing of a timer in the PLC operating system is influenced by the following commands. All running
timers are stopped and initialized when one of the following actions occurs:

 Abort PLC program

 RUN/STOP switch from RUN -> STOP
 Warm or cold start
T-OFF DELAY:
Fig.5.11.1
PARAMETERS
DESCRIPTION
The 1-0 edge of the input IN is delayed by the time PT at the output Q. If the input IN returns to
1 level before expiry of the time PT, the output Q retains 1 level.
The time elapsed can be consulted at the output ET and the preset time value at the input PT can be
modified when the timer is running. The preset time is specified in milliseconds. The time range which
can be specified is : 1 ms ... 24.8 days.
Maximum time offset at the output : < 1 cycle time
Meaningful range for PT :> 1 cycle time.
Fig.5.11.2

5.5.3 PROGRAM:-
The figure below is the program written in the FBD language:
As shown in the figure,
The input of PLC %I62.00 is connected to Forward PB.

The input of PLC %I62.01 is connected to Stop PB.
The input of PLC %I62.02 is connected to Reverse PB.
The input of PLC %I62.03 is connected to Speed enable switch.
The inputs of PLC %I62.04, 05 and 06 is connected to Selector switch.
The input of PLC %I62.07 is connected to Thermal O/L relay.
The output of PLC %O62.00 is connected to RYB supply contactor.
The output of PLC %O62.01 is connected to 1st set resistance relay.
The output of PLC %O62.02 is connected to 2nd set resistance relay.
The output of PLC %O62.03 is connected to 3rd set resistance relay.
The output of PLC %O62.04 is connected to BYR supply contactor.
The output of PLC %O62.05 is connected to Speed enable indicator.

Fig 5.12
This program is been sent into the PLC using an RS-232 cable .This program is written as per the requirement of
the panel design

ADVANTAGES :
 Troubleshooting is Easier and Faster..
 Easy to develop Programs
 Less amount of Space Needed
 Less Maintenance
 Easy to Monitor Inputs and Outputs by PC's
 Flexible
 Faster response time
 Less and simpler wiring
 Rugged and designed to withstand vibrations, temperature, humidity, and noise.
DISADVANTAGES:
 Cost of PLC is high

 PLC'S are designed by semiconductors, which are depends on thermal characteristics
 Efficiency is affected, due to power loss in rotor resistance circuit

PROJECT OUTCOME OR RESULT
 When the motor runs with full resistance in rotor circuit then the speed is observed on the
tachometer as 1160 rpm in forward in 1170 rpm in reverse rotation.
 The speed of induction motor will increases from 1160 rpm to 1212 rpm in forward and 1170
rpm to 1222 rpm in reverse rotation when the first set of resistance in rotor circuit is cut-off.
 The speed of induction motor will increases from 1212 rpm to 1296 rpm in forward and 1222
rpm to 1346 rpm in reverse rotation when the second set of resistance in rotor circuit is cut-off.
 The motor gains a speed of 1488 rpm which is nearer to rated speed when all the resistances are
cut-off from the rotor circuit.
CONCLUSION:
This PLC based system is highly reliable. Without changing in any hardware connection just by
simply changing the program in the PLC, the motor can be made to run in any of the two directions and
for any duration of time.
It is also possible to change the speed at any instant of time and to run at any one of three speeds for any
required duration without altering any hardware.
This system also used for one of the starting method of three phase slip ring Induction motor this system
not only reduces the starting current to a limit, but also develops high starting torque which is required in
many of the induction motor applications.
This can be applicable to run the lift, by changing the logic in a program and it can also be used for any
industrial applications.
This PLC based system requires less hardware compared to any microcontroller or microprocessor based
system.
Programmable Logic Controllers (PLC) are widely used in industrial control because they are
inexpensive, easy to install and very flexible in applications. A PLC interacts with the external world
through its inputs and outputs.

SCOPE FOR FUTURE EXPANSION:
By connecting analog extension module analog quantities like speed of the motor and voltage can
be read and a closed-loop control system can be implemented.
By using analog extension modules it is possible to get the characteristics like speed-torque,
speed-frequency, torque-current etc.
By connecting required number of electrical devices, it can extend to develop the SCADA
system and those types of systems are more reliable.

Appendix
ABB AC-31 50 SERIES PLC:
1 CS31 twisted-pair remote unit

8 opto-isolated inputs 24VDC type PNP or NPN
6 relay outputs 250V A.C. / 2A or 6 transistor outputs:
2 outputs 24 VDC, 1A
4 outputs 24 VDC , 0.5 A
The variables used by the AC 31 central units are of different types:

 Bit variables (status 0 or 1)
 Word variables (range -32768 to 32767)
 Double word variables (range -2147483648 to 2147483647)
 Texts (ASCII characters)
Time values for the timer functions:

KD01.00...KD07.15 double word constants
MD00.00...MD07.15 internal double words.

ABBREVIATIONS
SMPS - Switching Mode Power Supply
PLC - Programmable Logic Controller
FBD - Functional Block Diagram
SFC - Sequential Flow Chart
IL - Instruction List
LD - Ladder Diagram
NS - Synchronous speed
Rr - Rotor Resistance
Rs - Stator Resistance
Xr - Rotor Reactance
Xs - Stator Reactance
SCADA - Supervisory Control & Data Acquisition
DOL - Direct Online Starter

References
BOOKS:
1.) Dale R.Patrick, “Rotating Electrical machines and Power Systems”
2.) J.D. Edwards, “Electrical Machines”.
3.) V.U. Bakshi & U.A. Bakshi, “Electrical Machines”.
4.) www.wikipedia.com, PLC, http://en.wikipedia.org/wiki/PLC
5.) AC-31 GRAF software Programming Manual.

Starting and Speed Control of 3-O Slip R

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Starting and Speed Control of 3-O Slip R

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Starting & Speed control of 3-Ø slip ring IM motor

What happens if the motor is started as a normal induction motor?

2) v/f control method.

3) Rotor emf injection method.

4) Rotor resistance control method.

1 Department of Electrical & Electronics Engg.,

2.1 Construction of slip-ring induction motor:

2 Department of Electrical & Electronics Engg.,

Slip ring rotor:

2.2 Equivalent circuit of slip-ring induction motor:

3 Department of Electrical & Electronics Engg.,

4 Department of Electrical & Electronics Engg.,

2.3 Principle of operation:

Production of Rotating Magnetic Field:

5 Department of Electrical & Electronics Engg.,

6 Department of Electrical & Electronics Engg.,

Fig.2.6 represents the typical torque curve as a function of slip

7 Department of Electrical & Electronics Engg.,

2.4 Rotor resistance in slip-ring induction motor:

8 Department of Electrical & Electronics Engg.,

Why put resistance in series with the rotor?

9 Department of Electrical & Electronics Engg.,

2.5 STARTING AND SPEED CONTROL OF 3-PHASE SLIP-RING INDUCTION MOTOR

2.5.1 Starting methods:

1) Reduce heavy starting currents and prevent motor from overheating.

2) Provide overload and no-voltage protection.

 Direct on-line starter.

 Series Reactance method.

 Variable frequency drive.

 Rotor Resistance method of starting.

10 Department of Electrical & Electronics Engg.,

 Direct On-Line (DOL) starting:

11 Department of Electrical & Electronics Engg.,

 Series reactor connection:

 Variable frequency drive:

A variable-frequency drive starts a three-phase induction motor at a frequency low enough to

 Rotor resistance starting:

2.5.2 SPEED CONTROL METHODS:

1. Changing applied voltage.

2. Changing applied frequency.

3. Changing number of stator poles.

4. Changing the rotor circuit resistance.

12 Department of Electrical & Electronics Engg.,

 Changing applied voltage:

13 Department of Electrical & Electronics Engg.,

 Changing applied frequency:

Limitations of these methods are:

Fig.2.10 Characteristics of ‘v/f’ control

14 Department of Electrical & Electronics Engg.,

 Changing the number of stator poles:

 Changing the rotor resistance:

As we know the torque equation of induction motor is

And the slip corresponding to maximum/Breakdown torque is

15 Department of Electrical & Electronics Engg.,

Fig.2.11 Torque-speed characteristics for different rotor resistances

16 Department of Electrical & Electronics Engg.,

17 Department of Electrical & Electronics Engg.,

3.1 Working Of An Thermal Over Load Relay

A = Heated bimetal strips

E = Reparation bimetal strip

18 Department of Electrical & Electronics Engg.,

4.1 PROGRAMMABLE LOGIC CONTROLLER

A PROGRAMMABLE LOGIC CONTROLLER (PLC) is a digital computer used for automation