CHAPTER 5

Delta-Star Starter for Squirrel Cage Induction Motor

- Applications Demands High Starting Torque

5.1 Introduction

Induction Motors consume 60% of total electrical energy in industrialized countries. In

industry, more than 90% of the electrical motors are three phase squirrel-cage induction motors [3].
80% of Induction motor populations are less than 15KW, where efficiencies are generally lower and
over sizing possibility is very high. The motor load factor survey conducted indicates 20% of
induction motor population in industries in organized sector are loaded less than 30% of its rated
capacity. The Motive Power utilization survey conducted in India indicates the energy consumption
in Material handling equipment is 8% and having average load factor less than 30%. Applications
like Agitator, Aerator, Screw Conveyers and Conveyer belt demands high starting torque and low
running torque. For the above equipment, the load factor is always less than 33% during normal
operation.

The common problem one may encounter during the design and installation stages is the
over design due to the gross overestimation of the mechanical power required by the load [3]. The
main reason for over design is due to lack of knowledge, cushion added in multiple design stage.
The over sizing is common in smaller size induction motor application up to 18.5 HP, where
constant losses / iron losses are predominant. These leads to low operating load factor and poor
efficiency.

The use of squirrel cage induction motor is limited for low starting torque application. But in
general, due to maintenance free operation, it is common to use squirrel cage induction motor for
High Inertia load application. This will lead to over sizing of motors, which results in excess energy
consumption during normal running condition. An attempt was made to improve the operating
efficiency of oversized motor in High Inertia load application with the help of a special type of starter
called Delta-Star Starter. This starter starts the squirrel cage induction motor in Delta Connection to
meet the high starting torque and runs in Star connection to take care of running torque.

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5.2 Starting High Inertia Loads
There are number of considerations, when starting a high inertia load. It is important that
the whole system is engineered correctly to prevent field problems and equipment failure. A high
inertia load requires an extended starting time to reach full speed. Time taken for starting of a load
is a function of load inertia, load speed and starting torque developed by the motor, If Starting
Voltage / Current reduction will extend the starting time. During starting, there are two components
of torque that is delivered to the load. The work torque is the torque required for keeping the load
spinning at that speed and the acceleration torque is the torque that causes the load to increase in
speed. Acceleration torque is the difference between work torque and torque developed by the
motor. The reduction in starting voltage / current will also reduce the shaft torque of the motor. The
applied voltage, which in turn determines the rate of acceleration, governs acceleration torque.
There will be no acceleration torque, when the motor reached full speed. More the starting time
required for an application, it is better to select a higher frame size motor (GD2) for easy dissipation
of heat generated during starting [15]. The Table 5.1 shows the effect of starting methods on motor
selection for High Inertia applications.

Table 5.1. Effect of starting methods on motor selection for High inertia applications

Starting methods Starting Accelerating Motor starting Motor Frame size

Current torque time

Direct online 6 X IRated 2.4 X TRated 25 Seconds Standard frame size

Star Delta 2 X IRated 0.8 X TRated 85 Seconds Higher frame size

Soft Starter 3 X IRated 0.6 TRated 105 Seconds Higher frame size

5.2.1 Starter for High Inertia Load Applications

The Star-Delta starter is a commonly used starter for starting squirrel cage induction motor
to limit the starting current. The Star-Delta starter’s applications are limited to low starting torque
applications [15]. For high inertia load applications, the starter must be capable of withstanding the
high overload during starting for the duration of the start. With a high inertia load, to get the
machine to full speed in a reasonable time, a high starting torque must be presented to the load.
For High Inertia load applications, it is necessary to use Direct-on-line starter for squirrel cage

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induction or Rotor resistance starter for slip ring Induction motors. Squirrel cage Induction motor is
the commonly preferred drive up to 50HP Motor capacity application in High tension and extra high-
tension industrial establishments. The starting torque developed by the slip ring induction motor
with rotor resistance starter is higher than the squirrel cage induction motor for a same size. Even
though squirrel cage induction motor selected for High Inertia load applications due to ruggedness,
easy maintenance and relatively cheap compared to slip ring induction motor [5]. Especially smaller
size induction motor application up to 18.5 HP the Squirrel cage induction motor is popularly
selected because of its ruggedness and simple ON/OFF control logic in High Tension industries.

In general, majority of Low Tension (LT) Induction motor stator windings are connected in
Delta connection. The reason for delta connection is to reduce the manufacturing cost of the motor.
A delta connected induction motor delivers more output power than a star connected motor for
same volume of active materials used for fabrication. The starting torque developed by the motor is
directly proportional to the square of the supply voltage [18]. In case of Delta connection, the 100%
of supply voltage is applied to the each phase of the winding. In Star connection, only 58% of the
supply voltage is applied to each phase of the winding. The starting torque in delta connected
induction motor is three times than that of same motor, when connected in star connection [10].
The figure 5.1 shows the Slip versus Torque, Current characteristics of Squirrel Cage induction
motor in Star and Delta Connected mode.

Figure 5.1 Slip versus Torque, Current Characteristics of Squirrel cage Induction Motor
in Star and Delta Connected Mode

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5.2.2 Starting Torque Requirement

While selecting the rating of a motor for an application, it is important to consider the
starting torque requirement. The squirrel cage induction motors are purposely oversized for High
Inertia load applications to meet the starting torque without appreciable increase in temperature
during starting. This leads to lightly loaded conditions during running and lower operating efficiency.
The chance of over sizing of squirrel cage induction motor for High Inertia load application is very
high, in motor size less than 18.5 HP applications. The other reason for selecting squirrel cage
induction motor for High Inertia load application is due to limited availability of wound rotor motor up
to 18.5 HP rating. In the world motor population, 80% of motor population are less than 20HP.
When squirrel cage induction motors are selected for high inertia load applications, the load factor
is less than 30%. The iron losses in induction motors up to 18.5 HP size will be almost 30 to 50% of
the total motor losses [19].

5.3 Loss in a Standard Squirrel Cage Induction Motor

In smaller capacity Induction motors up to 18.5 HP size, the Iron loss is around 25 to 50%
of its full load copper loss. In 20 to 50 HP size induction motor, the ironless is around 20 to 25% of
its full load copper loss. The applied voltage variation plays a major role on variation in iron loss of
the motor up to 50 HP. The typical loss value for a 15 HP, 4 Pole, 415 Volts, 50Hz, 1460RPM,
standard squirrel cage Induction motor is shown in the Table 5.2

Table 5.2 Loss Break-up for 15 HP, 4 Pole, 415 Volts, 50 Hz, 1460 RPM Standard Squirrel
Cage Induction Motor

Sl. No Type of Loss Loss in Watts

1. Iron losses 455 Watts
2. Friction and Wind age 120 Watts
3. Load related losses (Copper Losses) 925 Watts
4. Total Losses 1500 Watts
Efficiency 88%
Courtesy: Siemens Limited, India

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5.4 Delta-Star Starter

The construction of Delta-Star Starter is similar to the Star-Delta Starter available

commercially in the market for squirrel cage Induction Motor. The Delta-Star Starter starts the
motor in Delta connection to develop high starting torque and run the motor in Star to minimize the
voltage related losses. The concept used in Delta-Star Starter is just reverse in case of Star Delta
Starter. In this type of starter, the Delta Contact is energized first and starts the motor in Delta
connection to meet the High starting torque demanded by the application and then the Star Contact
is energized and Delta contact de-energized to switch over to Star connection to meet the running
torque requirement and minimize magnetization losses.

This type of starter was tested with Squirrel Cage Induction Motor used for High Inertia
loads applications (Agitators, Mixers and Long conveyor belts) and their energy performance are
better than using direct on line Starter. The schematic representation of Delta-Star Starter is shown
in Figure 5.2.

Starting

Running

Figure 5.2 Schematic Representation of Delta-Star Starter

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 The Efficiency comparison of 3 HP, 4HP, 15HP 4 Pole, 415 Volts, 50Hz standard Induction
Motor in Star and Delta Connection mode of operation during running at low load factor are shown
in the Table .5.3, 5.4 and 5.5 [3].

Table 5.3 Efficiency Comparisons of 3 HP, 4 Pole, 415 Volts, 50 Hz standard Induction Motor in
Delta and Star Connection Mode of Operation

Sl.No Load Efficiency in Delta Efficiency in Star Efficiency Improvement in Star

Factor Connection Mode Connection Mode Connection Mode
1. 10% 50% 70% 20%
2. 20% 66% 78% 12%
3. 30% 73% 77% 4%
4. 40% 77% 76% - 1%

Table 5.4 Efficiency Comparisons of 4 HP, 4 Pole, 415 Volts, 50 Hz Standard Induction Motor in
Delta and Star Connection Mode of Operation

Sl.No Load Efficiency in Delta Efficiency in Star Efficiency Improvement in Star

Factor Connection Mode Connection Mode Connection Mode
1. 10% 52% 72% 20%
2. 20% 70% 80% 10%
3. 30% 76% 79% 3%
4. 40% 79% 77% - 2%

Table 5.5 Efficiency Comparisons of 15 HP, 4 Pole, 415 Volts, 50 Hz Standard Induction Motor in
Delta and Star Connection Mode of Operation

Sl.No Load Efficiency in Delta Efficiency in Star Efficiency Improvement in Star

Factor Connection Mode Connection Mode Connection Mode
1. 10% 58% 72% 14%
2. 20% 72% 82% 10%
3. 30% 80% 84% 4%
4. 40% 82% 82% 0%

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5.5 Where from Energy Savings

The Squirrel cage induction motor selected for High Inertia load application, leads to lightly
loaded conditions during normal running. When the load factor is always less than 33% of its full
load, it can be made to run in star connection to minimize the losses by installing Delta-Star Starter.
While converting delta to star connection in case of motor loaded less than 33%, the applied
voltage across each phase of the winding is reduced to 58% [18]. The reduction in applied voltage
will results in reduction in magnetization current and in turn reduces the flux. In case of lightly
loaded motor, the flux utilization is less compared to the flux set-up. This reduction in voltage will
reduce the capacity to 33 % of its earlier capacity and results in reduction in magnetization loss.
Thus it improves the Efficiency of the motor. The major factor governing the efficiency in this case
is due to the reduction in magnetization loss. Especially up to 50 HP Standard Induction Motors,
the Iron losses are reasonable amount of the total loss of the Motors during energy conversion.

Magnetization losses of Induction motor vary with respect to the applied voltage. The
magnetization losses increase exponentially with increase in voltage. The figure 5.3 shows that
how the magnetization losses vary with respect to the motor voltage.

Figure 5.3 Motor Magnetization Losses versus Motor Voltage

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5.6 Advantage of Star Connection during Running

Star connection is possible for the Induction Motor always loaded below 33% during normal
running to improve its operating efficiency. The star connection will result in
a. Capacity Reduction: motor capacity is directly proportional to the square of the system
voltage. The applied voltage across each phase of the motor winding in Star connection during
running is 67% of Delta connection. The 33% reduction in system voltage reduces the capacity
by 67%. The capacity of the Delta connected induction motor is reduced to 33% of its rated
capacity value in case of star connection.
Capacity of Motor ∝ V2 … 5.1
b. Load Factor Improved: For the lightly loaded motors by reducing the system voltage by
changing the winding configuration from Delta connection to Star connection during normal
running will result in reduction in capacity and improve the load factor.
c. Drop in Magnetization Loss: The magnetization loss depends upon the square of the voltage.
The reduction in system voltage will minimize the Magnetization losses.
d. Power Factor Improved: The Power Factor is the phenomena specifying the quality of flux
utilization. In case of lightly loaded motors, effective flux utilization is less. Reducing the system
voltage will reduce the flux and increase in the flux utilization, ultimately results in improved
Power Factor.
e. Load Current drops: Due to the improved Power Factor, the load current will drop compared
to the lightly loaded condition. This reduction in current will result in reduction in stator and rotor
copper loss.
f. Improved Efficiency: Thus the entire above factor is ultimately results in improved efficiency
compared to the earlier case.

5.7 Delta-Star Starter Applications

Delta-Star Starters are installed in few Cement industries for High Inertia load applications
using squirrel cage induction motors up to 50 HP size and operating satisfactorily without affecting
the production quality and quantity. The successful trail application selected for installation of Delta-
Star Starter was the slurry agitator, conveyor belt in Cement industries. In slurry agitator, the
starting torque was very high and running torque is less. In these cases, the motor is started in
delta to meet the initial starting torque requirement and run in star connection to minimize voltage

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related losses. Star Delta Star converter is ideal choice to save energy in case of lightly loaded
motor having load factor less than 33% and not subjected to load fluctuations. Similarly the starting
torque of Belt conveyors is high and running torque is less. An implemented case study in a wet
cement plant is discussed below.

5.7.1 Install Delta-Star Starter for Slurry Agitator

In a Wet Cement Plant in Tamilnadu, India, the motor for the slurry agitator was designed
based on the starting torque requirement. In cement industry for constant speed, less than 50 HP
applications squirrel cage Induction motors are preferred because of less maintenance and
considering the environmental factors. Initially Direct On-line starter was installed to meet-out the
High Inertia load requirement. During a detailed energy audit conducted, power measurement
made in the slurry agitator drive indicates that, it was lightly loaded during running conditions. The
reason for the light loaded condition was due to design based on the starting torque requirement. It
was recommended to install Delta-Star Starter to minimize energy consumption during running
conditions. Delta-Star Starter was installed at 6 Nos. of slurry agitator motors in a wet cement plant,
which is subjected to High Inertia load. The slurry agitator runs for 16 hours per day for 330 Days in
a year.

The following observations were made:

Rated Capacity - 37.0 kW (50 HP)
Actual Load, when running with Direct Online Starter - 10.5 kW
Actual load, when running in Delta-Star Starter - 9.5 kW

The annual energy saving benefits achieved by installing Delta-Star Starter for 6 Nos. of
slurry agitator application was 31680 KWH.

5.8 Limitation of Delta-Star Starter

Delta-Star Starter is practice is applicable up to 50 HP standard induction motor. The

reason for the capacity limitation is the iron loss will be a reasonable magnitude of the full load
copper loss up to 50 HP standard induction motor. In higher HP motor, the iron loss is 5 to 15 % of
the full load copper loss, since the reduction in iron loss by star conversion is negligible. Adopting

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this technique for energy efficient motor is limited, since the iron loss also partially varied by varying
the magnetic saturation; hence even during lightly loaded condition it operates at maximum
efficiency due to the optimal design and improved magnetic material used.

5.9 Future Applications

The squirrel cage induction motors are designed by keeping the Voltage to frequency (V/F)
ratio at constant factor. For a 415 Volts 50 Hz rated LT supply system the V/F ratio value is 8.3.
When operating the Delta connected motor in Star connection there is a deviation in V/F ratio. This
deviation in V/F ratio due to Star connection affects the energy performance of the motor and
variation in energy efficiency is 2 to 3% in small size motor. The energy performance of the motor
in Star connection is better than compared with the lightly loaded condition of Delta connection
even though there is a change in V/F ratio. An attempt was made to study the performance of dual
rated motors, designed to operate in star or delta connection. The energy performance of 2HP,
4Pole, 230/400 Volts, Delta / Star, 50Hz Siemens make Squirrel Cage induction motor performance
was analysed in Laboratory in Star and Delta connected mode to meet various load conditions. The
performance parameters are shown in the Table 5.6.

Table 5.6 Performance of 2HP, 4 Pole Dual Rated Squirrel cage Induction Motor
Sl. No. Parameter In Star Connected In Delta Connected
Mode of Operation Mode of Operation
1. Rated Capacity 2 HP 2 HP
2. Rated Voltage 230 Volts 400 Volts
3. Rated Current 5.9 Amperes 3.4 Amperes
4. Supply Frequency 50 Hz 50 Hz
5. No-load Current 1.09 Amperes 2.57 Amperes
6. No-load power consumption 97.2 Watts 290 Watts
7. No-load Power factor 0.39 Lagging 0.28 Lagging
8. No-load Speed 1465 RPM 1460 RPM
9. Efficiency at 25% Load 64% 52%
10. Efficiency at 50% Load 71% 63%
11. Efficiency at 75% Load 78% 73%
12. Efficiency at 100% Load 82% 80%

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 The energy performance of Star connected induction motor was excellent during running
condition in Star connected mode and Starting torque delivered at the time of starting in Delta
connection mode also equal to the conventional Delta Connected induction motor. In future
applications to keep V/F ratio constant during running condition, this work proposes to select a Star
connected squirrel cage induction motor for High Inertia load application (Up to 18.5 HP
applications) and install Delta-Star Starter for these applications. This Star connected Squirrel cage
induction motor can start the motor in Delta connection mode to meet the High Inertia load
requirement and run the motor in star connected mode to minimize power consumption. Since the
V/F ratio is not affected during running condition the performance can be improved by another 1 to
3% depending upon the size.

5.10 Summary

The performance of Squirrel Cage induction motor with Delta-Star Starter was analysed
experimentally in laboratory and also tested in industrial drive applications, where the load factor is
always less than 33%. The operating efficiency improved 5 to 15% depending upon the induction
motor size and load factor. In Smaller size squirrel cage induction motor (0.5 HP to 10 HP), the
saving potential is high compared to larger size, since iron losses is reasonable amount of total
copper loss of a motor. The Delta-Star Starter operates normally without affecting the process / unit
operation. This thesis work recommend to install Delta-Star Starter or High starting torque / inertia
applications using squirrel cage induction motor up to 50HP capacity to conserve energy, when
load factor is always less than 33%. The Delta-Star Starter also improves the power factor and
minimizes the demand on power supply system. In future the industries can select a Star
connected motor for High Inertia load application and install Delta-Star Starter, to start the motor in
Delta to meet the High Starting Torque and run the motor in Star to conserve energy.

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