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Ect211 PDF
Ect211 PDF
..........................................................................
G. Baurand
V. Moliton
Foreword
Gilles BAURAND
Vivien MOLITON
Contents
1 Introduction p. 4
2 Brief guide to electric motors 2.1 The various types of motor p. 5
2.2 The applications of low-voltage motors p. 6
3 Causes of faults and their consequences 3.1 Internal faults in the motor: p. 7
Damage to the stator or rotor winding
3.2 Faults external to the motor: p. 8
Phenomena related to the motor power supply
3.3 Faults external to the motor: p. 11
Phenomena related to the use of the motor
3.4 Summary p. 12
4 Protection functions 4.1 Short-circuit protection p. 13
4.2 Overload protection p. 14
4.3 Selection table for protection relays p. 19
4.4 “Motor circuit-breakers” (thermal-magnetic circuit-breakers) p. 20
5 Motor starters 5.1 Background p. 21
5.2 The basic functions of motor starters p. 21
5.3 The special case of electronic starters and variable speed drives p. 23
5.4 A complementary function: communication p. 23
5.5 Motor starters and coordination p. 24
5.6 Control and protective switching devices (CPS) p. 26
5.7 Discrimination p. 27
5.8 Example p. 27
6 Conclusion p. 29
Appendix 1: Modular system of the Tesys U starter-controller p. 30
Appendix 2: The main starting modes p. 31
Appendix 3 : Bibliography p. 35
All electric motors have operating limits. Exceeding To avoid these mishaps, or at least limit their
these limits will result, sooner or later, in the consequences and prevent them from causing
destruction of the motor and also of the machines damage to equipment and disturbances in the
driven by it, causing immediate stoppages and line supply, protective systems must be used.
lost production. They can isolate equipment to be protected from
This form of load, which converts electrical the line, by tripping breaking devices in response
energy to mechanical energy, can be the site of to the detection and measurement of variations
mishaps due to electrical or mechanical factors. in electrical values (voltage, current, etc.).
b Electrical Each motor starter must therefore incorporate:
v overvoltage, voltage drop, unbalance, or phase b short circuit protection, to detect and cut off, as
loss, causing variations in the current drawn; quickly as possible, abnormal currents which are
v short circuits where the current can reach generally more than 10 times the nominal current
destructive levels for the load; (In)
b Mechanical b overvoltage protection, to detect current
increases up to approximately 10 In and cut off
Rotor stall, momentary or prolonged overload
the starter before the heating of the motor and
leading to an increase in the current drawn by
the conductors damages the insulation
the motor and consequently a dangerous heating
of its windings. This protection is provided by specific devices
such as fuses, circuit-breakers, overload relays
The cost of these mishaps can be high. It includes
or combination devices offering several types of
lost production, the loss of raw materials, the
protection.
repair of the production equipment, the loss of
production quality, and delays in delivery. The Note: Protection against “ground faults”, which
economic imperative of increasing competitiveness includes protection of personnel and fire-proofing,
for businesses implies the reduction of costs related is not covered in this document, since it is
to the loss of service continuity and low quality. usually provided as part of the power distribution
system for a piece of equipment, a workshop or
These mishaps can also have dramatic
a whole building.
consequences for the safety of personnel coming
into direct or indirect contact with the motor.
Stator
windings
Fig. 3 : The windings of motors are the parts which are most vulnerable to electrical faults and operating
mishaps.
100
75
10
50
1 25
0
0.1 °C In 1.05xIn 1.1xIn 1.15xIn Current
0 20 40 60 80 T T+10 T+20 T+30 °C
Fig. 4 : Change in the insulation resistance of motor Fig. 5 : Service life of motors as a function of their
windings as a function of their temperature operating temperature or current consumption
3.2 Faults external to the motor: Phenomena related to the motor power supply
Overvoltage
Any voltage applied to equipment where the
V
peak value exceeds the limits of a range defined
by a standard or a specification is an overvoltage
(see Schneider Electric “Cahiers Techniques”
nos. 151 and 179).
Temporary or permanent overvoltages (see
Fig. 6 ) can have different origins, namely:
b atmospheric (lightning strikes)
b electrostatic discharges t
b operation of equipment connected to the same
network
b etc.
Their principal characteristics are shown in the
table in Figure 7 hereafter.
These disturbances, which are superimposed on Fig. 6 : Example of overvoltage.
the line voltage, can act in two ways:
b in common mode, between the active
conductors and the ground In most cases, the effect of an overvoltage is
b in differential mode, between the different a dielectric breakdown in the motor windings,
active conductors which destroys the motor.
Vmean =
(V1 + V2 + V3 ) 0.7
Voltage
unbalance
3 0 1 2 3 4 5 (%)
The consequences of an unbalance of the
voltages applied to a motor are a decrease in Fig. 10 : Derating of a motor as a function of the
the useful torque and an increase in losses; the voltage unbalance in its power supply.
unbalances give rise to an inverse component
h1
h5
h total (h1+h5)
Fig. 12 : Sinusoidal voltage reading, including 5th order harmonics.
3.3 Faults external to the motor: Phenomena related to the use of the motor
Motor starting: excessively long and/or
frequent starting IS
The starting phase of a motor is the period IN
required for it to reach its nominal rotation speed.
The starting time (tS) depends on the resistive
20
torque (Tr) and the motor torque (Tm). An increase
in the resistive torque, due to the load to be driven,
together with a decrease in the motor torque, due 15
to a line voltage drop (20 to 30% of Un), causes
an increase in the motor starting time as follows:
10
π N 9
tS (s) = J
30 Tm − Tr 8
where 7
J is the global moment of inertia of the moving 6
frames 5
N(r.p.s.) is the rotation speed of the rotor.
Because of its intrinsic characteristics, each 4
motor can only withstand a limited number of
3
starts, generally specified by its manufacturer (as
the number of starts per hour). t (s)
3 4 5 7 10 15
Similarly, each motor has a maximum starting Fig. 13 : Permissible start times of motors as a function
time which is a function of its starting current of the ratio between starting current and nominal current.
(see Fig. 13 ).
3.4. Summary
This summary, shown in table form in Figure 14, In all cases, two forms of protection are always
shows the possible causes, the probable effects required for motors:
and the established consequences of each type b short-circuit protection
of fault. b overload (overheating) protection
Fig. 14 : Summary of the faults which can affect a motor, with their causes, effects and consequences.
The values in the table above are provided for guidance only. In reality, the derating of a motor
depends on it size, its insulation class, its type of construction (self-cooled or forced-cooled, IP 23 or
IP44 degree of protection, etc.), and varies according to the manufacturer
Note: The nominal power which is generally shown on a motor plate is specified by the manufacturer
for a continuous service S1 (operation at constant speed and for a long enough time to reach
thermal equilibrium).
There are other standard services, such as temporary service S2, or periodic intermittent services
S3, S4 and S5 for which the motor manufacturer specifies an operating power, different from the
nominal power, for each case.
Fig. 19 : Derating factors of motors according to their operating conditions.
Current conductor
Blade with high
coefficient of expansion
Support forming
Blade with zero fixed point
coefficient of
expansion Bimetallic strip after heating
Current input
Trip release
system
Fig. 23 : View of the inside of a thermal overload relay and detail of one of its bimetallic strips.
Computer
I> I> I>
Modbus network
Multi-function
M PTC probes protection relay M M
3a 3a 3a
Type of relay Overload relay PTC probe relay Overload relay Multi-function
(thermal or relay
electronic)
Causes of heating:
Overload
Rotor locking
Phase failure
Ventilation fault With PTC probe
Shaft bearing seizing With PTC probe
Excessive starting time Class 20 or 30
Demanding service With PTC probe
Torque shocks With PTC probe
Some LR2K, LRD, LT3 LR97D & LT47 LT6
Telemecanique LR9D, LR9F
references Tesys U : Standard or Multi-function CU*
expandable CU*
(*) CU: Control Unit Entirely suitable Possible solution Unsuitable (no protection)
5.1 Background
A motor starter has four basic functions: b Power: speed adjustment, progressive starting,
b Isolation phase inversion, etc.
b Short-circuit protection b Control: auxiliary contacts, time delay,
b Overload protection communication, etc.
b Control (on - off). In the design of a motor starter, the functions
Each motor starter can be enhanced with are distributed in different ways, as shown
additional functionality according to the schematically in Figure 34 .
application requirements. These relate to:
M M M
Motor Motor Motor
Fig. 34 : The various functions and their combinations forming a motor starter.
Fig. 35 : The different operating categories of contactors according to their intended applications,
as shown in IEC 60947-1.
5.3 The special case of electronic starters and variable speed drives
Starting asynchronous motors by direct connection Electronic variable speed drives and starters
to the line supply is the solution which is most therefore have integrated protection. Modern
common, most economical and most suitable for a variable speed drives generally provide overload
wide range of machines. However, this may entail protection for motors and self-protection. On the
constraints (such as the inrush current on starting, basis of the current measurement and data on
mechanical shocks on starting, the impossibility the speed, a microprocessor calculates the
of controlling acceleration and deceleration and motor temperature increase and sends an alarm
the impossibility of varying the speed) which may or trip signal if the heating is excessive. Variable
be troublesome for some applications, or even speed drives, and in particular frequency
incompatible with the desired operation of the inverters, are also often fitted with protection
machine. Electronic starters and variable speed against:
drives (see Fig. 36 ) can overcome these problems, b short-circuits between phases and between
but the conventional protection described above phase and ground
is ineffective with equipment which modulates
b overvoltages and voltage drops
the electrical energy supplied to the motor.
b phase unbalance
b single-phase operation
Additionally, data produced by the thermal
protection incorporated in the variable speed
drive can be exchanged with a PLC or a
supervisor via the communications link provided
in the more advanced variable speed drives and
starters.
For further information about electronic starters
Fig. 36 : Variable speed drive (Telemecanique ATV58H). and variable speed drives, see Schneider-
Electric “Cahier Technique” no. 208.
1/L1
1/L2
1/L3
protection (against overload and short circuit) Power base unit
simultaneously; they are also designed to enable
control to be provided in short-circuit conditions. Control
They can also provide complementary functions units
such as isolation, enabling them to perform all the
functions of a “motor starter”. They conform to IEC
60947-6-2, which in particular defines the rated
values and the operating categories of CPS, and Control unit
to the principles of IEC 60947-1 and 60947-4-1.
The various functions of a CPS are combined
2/T1
4/T2
6/T3
and coordinated to provide continuity of service
for all currents up to the rated breaking capacity
for short-circuit operation, Ics, of the device. The Fig. 41 : Example of a modular CPS (Telemecanique
system may or may not incorporate a single Tesys U starter-controller).
device, but its characteristics are always rated as
if for a single device. Additionally, the guarantee
general-purpose “power base unit” or “sub-base”
of “total” coordination between all the functions
rated at 32 A (see Fig. 42 ).
gives the user a simple choice of an optimal
protection device which is easy to use. Additional functionality can also be installed, for
the following aspects:
Even if it takes the form of a single device, a
CPS can provide a degree of modularity equal b power: inverter unit, limiter
to, or even greater than, that of a “three product” b control:
motor starter. This is true of the Telemecanique v function modules: alarms, motor load,
Tesys U starter-controller (see Fig. 41 ). This automatic reset, etc.
allows a control unit integrating the protection v communication modules: AS-i, Modbus,
and control functions for motors from 0.15 A to Profibus, CAN-Open, etc.
32 A to be added, or changed at any time, on a v auxiliary contact modules, additional contacts.
D3 D2 Discrimination in processes
For process control equipment (production lines,
chemical production units, etc.), the
discrimination methods most commonly used
Fig. 43 : Discrimination between two circuit-breakers between motor starters and the electrical line
D1 and D2 connected in series, where the same fault supply to these processes are generally current-
current is flowing through both, requires that only the based and time-based. In most cases,
circuit-breaker D2 downstream of D1 should open discrimination is provided by the limiting or ultra-
limiting capacity of the motor starters.
5.8 Example
The aim is to select a motor starter for protecting b Short-circuit current of the installation calculated
and controlling a lifting pump where continuity of in relation to the equipment: Isc = 35 kA
service is essential. b Control voltage: 230 V.
D.O.L. starters with circuit-breaker and thermal overload relay – “3-product” solution, type 2 coordination
Standard power ratings of 50/60 Hz three-phase Circuit-breaker Contactor Thermal overload
motors in Category AC-3 relay
400/415 V 440 V 500 V Ref. Rating FLAm Ref.(2) Ref. Setting
(1)
P Ie Iq P Ie Iq P Ie Iq range
kW A kA kW A kA kW A kA A A A
GV2 L 0.08 0.22 130 0.06 0.19 130 - - - GV2 L03 0.4 5 LC1 D09 LRD 02 0.16…0.25
or LE03
0.09 0.36 130 0.09 0.28 130 - - - GV2 L03 0.4 5 LC1 D09 LRD 03 0.25…0.40
- - - 0.12 0.37 130 - - - or LE03
0.12 0.42 130 - - - GV2 L04 0.63 8 LC1 D09 LRD 04 0.4…0.63
0.18 0.6 130 0.18 0.55 130 or LE04
LC1 D
………
3 6.5 130 - - - - - - GV2 L14 10 10 LC1 D09 LRD 12 5.5…8
or LE14
- - - - - - 4 6.5 10 GV2 LE14 10 138 LC1 D12 LRD 12 5.5…8
- - - - - - 4 6.5 50 GV2 L14 LC1 D12 LRD 12 5.5…8
4 8.4 130 GV2 L14 10 138 LC1 D09 LRD 14 7…10
LR D or LE14
Solution: GV2 L14 + LC1 D09 + LRD 14
TeSys U starter-controllers – “1 product” solution, total coordination
- Power base
Rated short-circuit breaking capacity (Isc)
Volts 230 440 500 690
kA 50 50 10 4
Note: For higher values, use limiters. At 690 V, use phase barrier LU9 SP0.
Connection Rating Ref.
Power Control y 440 V 500 V 690 V
A A A
Screw clamp Screw clamp 12 12 9 LUB 12
32 23 21 LUB 32
- Control units
Maximum standard power ratings of Setting Clip on power Ref. to be
50/60 Hz single-/three-phase motors range base rating completed with
LUB 12 400/415 V 500 V 690 V code indicating
kW kW kW A A voltage
Advanced control – Pressing the Test button on the front panel simulates tripping on thermal overload.
Class 10 for three-phase motors
0.09 - - 0.15…0.6 12 and 32 LUCB X6pp
0.25 - - 0.35…1.4 12 and 32 LUCB 1Xpp
1.5 2.2 3 1.25…5 12 and 32 LUCB 05pp
5.5 5.5 9 3…12 12 and 32 LUCB 12pp
7.5 9 15 4.5…18 32 LUCB 18pp
15 15 18.5 8…32 32 LUCB 32pp
Existing control circuit voltages
Volts 24 48…72 110…240
c BL
a B
c or a - ES FU
Solution: LUB12 + LUCB 12 FU
Fig. 44 : Two solutions in which good coordination between the different functions of a motor starter is guaranteed
(source: Telemecanique).
C Id / In
I
Cmax
Cn Acceleration
torque Cr If (Cr)
Cd In
Resistive torque
N N
N1 Nn N1 Nn
In the power network
Starting current Large overcurrent (5 to 10 In)
Brownout Considerable
Harmonic disturbance Considerable during starting
Power factor Low during starting
In the motor
Number of successive starts Limited (thermal withstand)
Available torque Low during starting (see graph)
Temperature stress Very considerable (rotor)
In the mechanism
Stress on couplings Very considerable
Suitable load types Low-inertia load
Fig. 46 : Graphs and summary of the induced effects of the DOL starting mode.
Star-triangle starting
U V W U V W
The principle of this mode is that the motor is
started by coupling the windings in star L1 L2 L3
configuration under the line voltage (see Fig. 47 ),
which is equivalent to dividing the nominal 1 3 5
voltage of the motor in star configuration by 3. Q1 X Y Z X Y Z
The peak starting current is then divided by 3, 2 4 6
i.e. Is = 1.5 to 3 In.
This is a simple and economical starting mode
which reduces the current peak on starting (see 1 3 5 1 3 5 1 3 5
Fig. 48 next page). KM2 KM3 KM1
It can only be used if: 2 4 6 2 4 6 2 4 6
C in ∆ I
Cmax I in ∆
4
2
2 I in Y
C in Y
Cr If (Cr)
1 In
Resistive torque
N N
N1 Nn N1 Nn
In the power network
Starting current Low overcurrent (1.5 to 3 In)
Brownout Considerable on change of coupling
Harmonic disturbance Considerable during starting
Power factor Degraded during starting
In the motor
Number of successive starts 2 to 3 times greater than in direct connection
Available torque Reduced during starting (1/3 Cn)
Temperature stress Lower than in direct connection
In the mechanism
Stress on couplings Lower than in direct connection
Suitable load types Low-inertia
Fig. 48 : Graphs and summary of the effects of the star-triangle starting mode.
L1 L2 L3 Autotransformer starting
1 3 5 The motor is supplied at reduced voltage by
means of an autotransformer which is switched
Q1 out of the circuit after starting.
2 4 6
Ic Id
1 3 5 1 3 5 6
I∆ (direct)
KM1 KM1
5
2 4 6 2 4 6
I (stage 1)
R1 R3 R5 with resistances
4
I (stage 2)
3 without
R2 R4 R6
resistance
2
1 3 5
F2 1
2 4 6
N
U V W 50 100
Torque
M Cm (stage 2)
3
1.5 C∆ (direct)
Fig. 49 : Electrical diagram and sequence of a
rheostatic stator starter. 1
Cm (stage 1)
This starting mode avoids power cuts during the 0.5
starting phase; it can greatly reduce the Cresistive
magnetizing current peaks (transients). N
50 100
However, the starting current remains high, at about Fig. 50 : Current and torque graphs for a rheostatic
4.5 In. This starting mode causes a considerable stator starter.
loss of torque and power (see Fig. 50 ).
L1 L2 L3
Stage 1
L1 L2 L3
U V W
M
K3 K2 3
U1 V1 W1
Stage 2 Stage 3
L1 L2 L3 L1 L2 L3
U V W
U3 M
3
V3
U V W
W3
U V W M
U2 V2 W2 3
M K1
3
Cm (1er tps)
0,5
Crésistant
N
50 100
Fig. 52 : Current and torque graphs for an Fig. 53 : Progressive starting and deceleration unit
autotransformer starter. (Telemecanique Altistart 01).
Standards Miscellaneous
b IEC 60034-26: Rotating electrical machines. b Schémathèque Technologies du contrôle
b Part 26: Effects of unbalanced voltages on the industriel, Edition CITEF - Collection Technique
performance of three-phase induction motors. Telemecanique 1994
b IEC 60364, NF C 15-100: Low-voltage b Utilisation industrielle des moteurs à courant
electrical installations. alternatif, TEC & DOC, Schneider-Electric 2001 -
Jean Bonal
b IEC 60947-1: Low-voltage switchgear and
controlgear - Part 1 : General rules. b Protections électriques des alternateurs et
moteurs, Techniques de l’Ingénieur no. D 3775 -
b IEC 60947-2: Low-voltage switchgear and
Bernard Guigues
controlgear - Part 2 : Circuit-breakers.
b Protections électriques des alternateurs et
b IEC 60947-4-1: Low-voltage switchgear and
moteurs, Techniques de l’Ingénieur no. D 4820 -
controlgear - Part 4-1: Contactors and motor-
Jacques Verschoore
starters - Electromechanical contactors and
motor-starters. b Guide d’installation et de maintenance des
Moteurs asynchrones triphasés fermés à cage
b IEC 60947-6-2: Low-voltage switchgear and
ou à bagues, Leroy Somer Document
controlgear - Part 6-2: Multiple function
equipment - Control and protective switching
devices (or equipment) (CPS).
b IEC 60947-8: Low-voltage switchgear and
controlgear - Part 8 : Control units for built-in
thermal protection (PTC) for rotating electrical
machines.
b IEC 61000-2-1: Electromagnetic compatibility
(EMC) - Part 2: Environment - Section 1:
Description of the environment - Electromagnetic
environment for low-frequency conducted
disturbances and signalling in public power
supply systems.
01-07