Basics of Industrial Motor Control: 440 Electrical and Electronic Drives

CHAPTER 20
Basics of Industrial Motor

Control
20.0 Introduction design control systems that are very
complex. The basic components are the
ndustrial control, in its broadest sense,
following:
encompasses all the methods used to
control the performance of an electrical l . Disconnecting switches
system. When applied to machinery, it
2. Manual circuit breakers
involves the starting, acceleration,
reversal, deceleration, and stopping of a 3. Cam switches
motor and its load. In this chapter we 4. Pushbuttons
will study the electrical (but not
5. Relays
electronic) control of 3-phase
alternatingcurrent motors. Our study is 6. Magnetic contactors
limited to elementary circuits because 7. Thermal relays and fuses
industrial circuits are usually too
8. Pilot lights
intricate to explain briefly. However,
the basic principles covered here apply 9. Limit switches and other special
to any system of control, no matter how switches
complex it may appear to be. 10. Resistors, reactors, transformers, and
capacitors
20.1 Control devices The ensuing list of Basic Components
Every control circuit is composed of a for Control Circuits illustrates these
number of basic components connected devices, and states their main purpose
together to achieve the desired and application. Fuses are not included
performance. The size of the here because they are protective devices
components varies with the power of rather than control devices. They are
the motor, but the principle of operation discussed in Chapter 26. The symbols
remains the same. Using only a dozen for these and other devices are given in
basic components, it is possible to Table 20A.
439
440 ELECTRICAL AND ELECTRONIC DRIVES
BASIC COMPONENTS FOR CONTROL CIRCUITS
Disconnecting switches
A disconnecting su'itch isolates the
motor from the power source. It
consists of 3 knife-switches and 3
line fuses enclosed in a Inetallic
box. The knife-switches can be
opened and closed simultaneously
by means of an external handle. An
interlocking mechanism prevents
the hinged cover from opening
when the switch is closed.
Disconnecting switches (and their
fuses) are se[ected to carry the
nominal full-load current of the
motor, and to withstand short-circuit
currents for brief intervals.
Figure 20.1
Three-phase, fused disconnecting switch rated
600 V, 30 A.
(Courtesy of Square D)
Manual circuit breakers

A ,'nanual circuit breaker opens and
closes a circuit, like a toggle switch.
It trips (opens) automatically when
the current exceeds a predeterlllined
limit. After tripping, it can be reset
manually. Manual circuit breakers
are often used instead of
disconnecting switches because no
fuses have to be replaced.
Figure 20.2
Three-phase cjrcujt breaker,
600 V, 100 A. (Courtesy of
Square D)
Cam switches
(Courtesy of
BASICS OF INDUSTRIAL MOTOR CONTROL
A can? ,nvitch has a oroup of fixed

contacts and an equal number of
moveable contacts. The contacts can
be made to open and close in a
preset sequence by rotating a handle
or knob. Cam switches are used to
eontrol the motion and position of
hoists, eallenders, machine tools,
and so on.
Figure 20.3
Three-phase surface-mounted cam switch, 230 V,
2 kW.
Klockner-Moeller)
44 1
Pushbuttons
A pushbutton is a switch activated by finger pressure.
Two or more contacts open or close
when the button is depressed.
Pushbuttons are usually spring
loaded so as to return to their
normal position when pressure is
removed.
Figure 20.4
Mechanical-interlocked
pushbuttons with NO (normally
open) and NC (normally closed)
contacts; rated to interrupt an ac
current of 6 A one million times.
(Courtesy of Siemens)
Control relays
A control relay is an electromagnetic
switch that opens and closes a set of
contacts when the relav coil is
(Courtesy of
energized. The relay coil produces a
strong magnetic field which attracts a
movable armature bearing the
contacts.
Control relays are mainly used in low-
power circuits. They include time-
delay relays whose contacts open or
close after a definite time interval.
Thus, a time-delay closing relay
actuates its contacts after the relay
coil has been energized. On the other
hand, a time-delay opening relay
actuates its contacts some time after
the relay coil has been de-energized.
Figure 20.5
Single-phase relays: 25 A, 1 15/230 V
and 5 A, 1 15 V. (Courtesy of Potter and
Brumfield)
Thermal relays
A thermal relay (or overload relay) is
a temperaturesensitive device whose
contacts open or close when the motor
current exceeds a preset limit. The
current flows through a small,
calibrated heating element which
raises the temperature of the relay.
Thermal relays are inherent time-delay
devices because the temperature
cannot follow the instantaneous
changes in current.
Figure 20.6
Three-phase thermal relay with
variable current setting, 6 A to 10
A.
Klockner-Moeller)
(continued)
BASIC COMPONENTS FOR CONTROL CIRCUITS
(Courtesy of
Magnetic contactors
A magnetic contactor is basically a
large control relay designed to open
and close a power circuit. It
possesses a relay coil and a magnetic
plunger, which carries a set of
movable contacts. When the relay
coil is energized, it attracts the
magnetic plunger, causing it to rise
quickly against the force of gravity.
The movable contacts come in
contact with a set of fixed contacts,
thereby closing the power circuit. In
addition to the power contacts, one
or more normally open or normally
closed auxiliary contacts are usually
available, for control purposes.
When the relay coil is de-energized,
the plunger falls, thereby opening
and closing the respective contacts.
Magnetic contactors are used to
control motors ranging from 0.5 hp
to several hundred horsepower. The
size, dimensions, and performance
of contactors are standardized.
Figure 20.7
Three-phase magnetic
contactor rated 50 hp, 575 V,
60 Hz. Width: 158 mm;
height: 155 mm; depth: 107
mm; weight: 3.5 kg. (Courtesy
of Siemens)
Pilot lights
A pilot light indicates the on/off state
of a remote component in a control
system.
Figure 20.8
Pilot light, 120 V, 3 W mounted in a
start-stop pushbutton station.
( Courtesy of Siemens)
Limit switches and special switches
(Courtesy of
A limit switch is a low-power
snap-action device that opens or
closes a contact, depending upon
the position of a mechanical part.
Other limit switches are sensitive
to pressure, temperature, liquid
level, direction of rotation, and so
on.
Figure 20.9a SWITCH Limit switch with one NC

contact; rated for ten million operations; position
accuracy: 0.5 mm. (Courtesy of Square D)
Figure 20.9b
Liquid level switch.
Square D)
(a) (b)
(Courtesy of
443
Proximity detectors
Proximity detectors are sealed devices that can detect
ohjects without coming in direct contact with them. Their
service life is independent of the number of operations.
They are wired to an external dc source and generate an
alternating magnetic field by means of an internal
oscillator. When a metal object comes within a few
millimeters of the detector. the magnetic field decreases,
which in turn causes a dc control current to flow. This
current can be used to activate another control device, such
as a relay or a programm'able logic controller. Capacitive
proximity detectors, based on a similar principle but
generating an ac electric field, are able to detect
nonmetallic objects, including liquids.
Figure 20.10
Proximity detector to monitor the loading of a conveyor
belt.
(Courtesy of are respectively called
Telemecanique, Groupe normally open contacts
Schneider) (NO) and nonnally
closed contacts (NC)
In order to and are designated by
understand the sections the following symbols:
that follow, the legends normally
in Table 20A should be
read before proceeding open contact (NO)
further.
-4 normally
20.2 Normally closed contact (NC)
open and 4...f20.3 Relay coil
normally exciting current
closed When a magnetic
contactor is in its de-
contacts energized or open
Control circuit position, the magnetic
diagrams always show circuit has a very long
components in a state air gap, compared to
of rest, that is, when when the contactor is
they are not energized closed. Consequently,
(electrically) or in the case of an ac
activated contactor the inductive
(mechanically). In this reactance of the relay
state, some electrical coil is much lower
contacts are open while when the contactor is
others are closed. They open than when it is
closed. Because the relay coil compared to

coil is excited by a the power handled by
fixed ac voltage, the the contactor
magnetizing current is Solution
much higher in the a. The inrush current in
open than in the closed the relay coil is
contactor position. In
other words, a 1=
considerable inrush S/E =
current is drawn by the 2970/
relay coil at the 120
moment it is excited. 24.75
This places a heavier A
than expected duty on b. The normal relay coil
auxiliary contacts that current when the
energize the coil. contactor is sealed
(closed) is
Example 20-1 S/
E=
A 3-phase NEMA size 212/
5 magnetic contactor 120
rated at 270 A, 460 V =
possesses a 120 V, 60 1.77
Hz relay coil. The coil A
absorbs an apparent
power of 2970 VA and c. The steady-state
212 VA, respectively. apparent control
in the open and closed power needed to
contactor position. actuate the relay coil
Calculate the is 212 VA. The
following: apparent power that
the contactor can
a. The inrush exciting handle is
current
b. The normal, sealed
exciting current 270 3
c. The control power = 215 120
needed to actuate the VA
TABLE 20A GRAPHIC SYMBOLS FOR

ELECTRICAL DIAGRAMS
445
32
APPLICATION
• identified by an appropriate letter
28 @
30 @
1. terminal; connection 2. conductors crossing 3.

conductors connected 4. three conductors 5. plug;
receptacle 6. separable connector 7. ground connection;
arrester 8. disconnecting switch 9. normally open contact
(NO) 10. normally closed contact (NC) 11. pushbutton
NO; NC 12. circuit-breaker 13. single-pole switch; three-
way switch 14. double pole double throw switch 15. fuse
16. thermal overload element 17. relay coil 18. resistor 19.
winding, inductor or reactor 20. capacitor; electrolytic
capacitor 21. transformer 22. current transformer; bushing
type 23. potential transformer 24. dc source (general) 25.
cell 26. shunt winding 27. series winding; commutating
pole or compensating winding 28. motor; generator
(general symbols) 29. dc motor; dc generator (general
symbols) 30. ac motor; ac generator (general symbols) 32.
3-phase squirrel-cage induction motor; 3-phase wound-
rotor motor 33. synchronous motor; 3-phase alternator 34.
diode 35. thyristor or SCR 36. 3-pole circuit breaker with
magnetic overload device, drawout type 37. dc shunt
motor with commutating winding; permanent magnet dc

generator 38. magnetic relay with one NO and one NC
contact. 39. NPN transistor 40. PNP transistor 41 . pilot
light
For a complete list of graphic symbols and references
see "IEEE Standard and American National Standard
Graphic Symbols for Electrical and Electronics
Diagrams" (ANSI Y32.2/lEEE No. 315) published by
the Institute of Electrical and Electronics Engineers,
Inc., New York, NY 1001 7. Essentially the same
symbols are used in Canada and several other countries.
Thus, the small brief description of its
control power function. The
(212 VA) can rectangles are
control a load connected by arrows
whose power is that indicate the
215 120/212 direction of power or
1015 times signal flow (Fig. 20. I l ).
greater. A one-line diagram
is similar to a block
20.4 Control diagram, except that
the components are
diagrams shown by their symbols
A control system can rather than by
be represented by four rectangles. The
types of circuit symbols give us an idea
diagrams. They are of the nature of the
listed as follows, in components;
order of increasing consequently, one-line
detail and diagrams yield more
completeness: information. A list of
typical symbols is
• block diagram
displayed in Table 20A.
• one-line diagram* The lines connecting
• wiring diagram the various
• schematic diagram components represent
two or more
conductors (Fig. 20.
Also called single-line diagram.
12).
A block diagram is
A wiring diagram
composed of a set of
shows the connections
rectangles, each
between the
representing a control
components, taking
device, together with a
into account the
447
physical location of the terminals and even the

color
Figure 20.11
Block diagram of a combination starter.
600 v thermal overload
pushbutton
relay
auxiliary contact Figure 20.12
One-line diagram of a combination starter.
600 V 3-phase
Figure 20.13
Wiring diagram of a combination starter.
3-phase
Figure 20.14 kind of diagram we

Schematic diagram will be using.
of a combination The reader
starter. should note that
of wire. These the four diagrams
diagrams are in Figs. 20.11 to
employed when 20.14 all relate to
installing the same control
equipment or when circuit. The symbols
troubleshooting a used to designate
circuit (Fig. 20.13). the various
A schematic components are
diagram shows all given in Table 20B.
the electrical
connections
between
20.5 Starting
components, methods
without regard to Three-phase squirrel-
their physical cage motors are
location or terminal started either by
arrangement. This connecting them
type of diagram is directly across the line
indispensable when or by applying reduced
troubleshooting a voltage to the stator.
circuit or analyzing The starting method
its mode of depends upon the
operation (Fig. power capacity of the
20.14). In the supply line and the
sections that type of load.
follow, this is the Across-the-line
starting is simple and
449
inexpensive. The main basic components: a

disadvantage is the disconnecting switch
high starting cur- and a starter. The
rent, which is 5 to 6 disconnecting switch is
times the rated full-load always placed between
current. It can produce a the supply line and the
significant line voltage starter. The switch and
drop, which may affect
starter are sometimes
other customers
mounted in the same
connected to the same
enclosure to make a
line. Voltage-sensitive
devices such as combination starter
incandescent lamps, The fuses in the
television sets, and high- disconnecting switch
precision machine tools are rated at about 3.5
respond badly to such times full-
voltage dips.
Mechanical shock is
another problem that
should not be
overlooked. Equipment
can be seriously
damaged if full-voltage
starting produces a
hammerblow torque.
Conveyor belts are
another example
where sudden starting
may not be acceptable.
In large industrial
installations we can
sometimes tolerate
across-the-line starting
even for motors rated Figure 20.15
up to 10 000 hp. load current;
Obviously, the fuses consequently, they
and circuit breakers do not protect the
must be designed to motor against
carry the starting sustained
current during the overloads. Their
acceleration period. primary function is
A motor control to protect the
circuit contains two motor and supply
line against ranging from 120 V

catastrophic to 600 V. The
currents resulting thermal relays trip
from a shortcircuit the circuit breaker
in the motor or whenever the
starter or a failure current in one of
to start up. Under the phases exceeds
normal start-up the rated value for a
conditions, the significant length of
fuses do not have time.
time to blow, even
though the initial
current is 6 to 7
times full-load
current. The fuse
rating, in amperes,
must comply with
the requirements of
the National Electric
Code.
In some cases the
disconnecting switch
and its fuses are
replaced by a manual
circuit breaker.
20.6 Manual Single-phase

manual starters (Fig.
across-the-line 20. 1 5) are
starters built along the same
principles but they
Manual 3-phase
contain only one
starters are
thermal relay. The
composed of a
thermal relays are
circuit breaker and selected for the
either two or three particular motor
thermal relays, all that is connected to
mounted in an the starter.
appropriate
enclosure. Such
starters are used for
small motors (10 hp
or less) at voltages
451
20.7 Ax. As can be

seen, these
Magneti contacts are
c normally open.
Contacts A must
across- be big enough to
the-line carry the startin o
current and the
starters nominal full-load
Magnetic across- current without
the-line starters overheating.
are employed Contact Ax is
whenever a motor much smaller
has to be because it only
controlled from a carries the
remote location. current of relay
They are also used coil A.
The relay coil
whenever the
is represented by
power rating
the same symbol
exceeds 10 kW.
(A) as the
Fig. 20. 16 contacts it
shows a typical controls.
magnetic starter Contacts A and
and its associated Ax remain closed
schematic as long as the coil
diagram. The is energized.
disconnecting 2. The thermal relay T
switch is external protects the motor
to the starter. The against sustained
starter has three overloads. * The
main components: relay comprises
a magnetic three individual
contactor, a heating elements,
respectively
thermal relay, and
connected in series
a control station.
with the three
We now describe phases. A
these components.
l . The inagnetic * The thermal relay is often
designated by the letters
contactor A
OL (overload).
possesses three
heavy contacts A
and one small
auxiliary contact
Figure 20.16a Three-phase across-the-

line magnetic starter, 30
hp, 600 V, 60 Hz.
(Courtesy of K/ockner-Moe//er)
disconnecting switch contactor thermal overload relay

4
IT2
IT3 c
s
t
a
r
t
c
o
n
t
r
o
l
s
t
a
t
i
o
n
T
---üreset
pushbutton
stop
Figure 20.16b
Schematic diagram of a 3-phase across-the-line magnetic
starter.
453
the motor against

sustained overloads.
Contact T opens
after a period of
time that depends
upon the magnitude
of the overload
current. Thus, Fig.
20. 17 shows the
tripping time as a
multiple of the rated
relay current. At
rated current
(multiple l ), the
- relay never trips, but
—..m
ultiple at twice rated
of the current, it trips after
curren an interval of 40 s.
t
settin The thermal relay is
g equipped with a
reset button
Figure 20.17
enabling us to
Typical curve of a thermal
overload relay, showing reclose contact T
tripping time versus line following an
current. The tripping time overload. It is
is measured from cold-
start conditions. If the preferable to wait a
motor has been operating few minutes before
at full-load for one hour pushing the button
or more, the tripping time to allow the relay to
is reduced about 30
percent. cool down.
3. The control station,
small, normally composed of start-
closed contact T stop pushbuttons,
may be located either
forms part of the
close to, or far away
relay assembly. It
from the starter. The
opens when the pilot light is optional.
thermal relay gets
too hot and stays Referring to Fig. 20.
open until the relay 16b, to start the motor
is manually reset. we first close the
The current rating disconnecting switch
of the thermal relay and then depress
is chosen to protect
To stop the motor,

we simply push the
stop button, which
opens the circuit to the
coil. In case of a
sustained overload, the
opening of contact T
produces the same
effect.
It sometimes happens
that a thermal relay will
trip for no apparent
reason. This condition
can occur when the
ambient temperature
Figure 20.18 around the starter is too
Three-phase across-the- high. We can remedy the
line combination starter, situation by changing the
150 hp, 575 V, 60 Hz. location of the starter or
The protruding knob by replacing the relay by
controls the disconnecting another one having a
switch; the pushbutton higher current rating.
station is set in the Care must be taken
transparent polycarbonate before making such a
cover. (Courtesy of change, because if the
Klockner-Moeller) ambient temperature
around the motor is also
too high, the occasional
the start button. Coil A tripping may actually
is immediately serve as a warnin o .
energized causing Fig. 20. 18 shows a
contacts A and Ax to typical combination
close. The full line starter. Fig. 20. 19
voltage appears across shows another
the motor and the pilot combination starter
light is on. When the
pushbutton is released
it returns to its normal
position, but the relay
coil remains excited
because auxiliary
contact Ax is now
closed. Contact Ax is
said to be a se(frsealing
contact.
ELECTRICAL AND ELECTRONIC DRIVES
Figure 20.19 Figure 20.20

Three-phase across-the-line combination starter Three-phase 5 kV starter for a 2500 hp cage motor. The
rated 100 hp, 575 V, 60 Hz. The isolating circuit medium- and low-voltage circuits are completely
breaker is controlled by an external handle. The isolated from each other to ensure safety. The
compartment is 2286 mm high, 610 mm wide, and 813
magnetic contactor is mounted in the bottom left-
mm deep. The entire starter weighs 499 kg. (Courtesy
hand corner of the waterproof enclosure. The small of Square D, Groupe Schneider)
600 V/ 120 V transformer in the lower right-hand
corner supplies Iowvoltage power for the control
circuit. (Courtesy of Square D) fuses. The contactor acts also as a disconnecting
switch and consequently the overall size is much
smaller than more conventional combination
equipped with a small step-down transformer
starters.
to excite the control circuit. Such
transformers are always used on high-voltage
starters (above 600 V) because they permit 20.8 Inching and jogging
the use of standard control components, such In some mechanical systems, we have to adjust the
as pushbuttons and pilot lights while reducing position of a motorized part very precisely. To
the shock hazard to operating personnel. accomplish this, we energize the motor in short
Fig. 20.20 shows a medium-voltage across- spurts so that it barely starts before it again comes
theline starter for a 2500 hp, 4160 V, 3-phase, to a halt. A double-contact pushbutton J is added
60 Hz squirrel-cage motor. The metal to the usual start/stop circuit, as shown in Fig.
compartment houses three fuses and a 3- 20.22. This arrangement permits conventional
phase vacuum contactor. The contactor can start-stop control as well as jogging, or inching. The
perform 250 000 operations at full-load following description shows how the control circuit
before maintenance is required. The 120 V operates.
holding coil draws 2 1 .7 A during pull-in, and If the jog button J is in its normal position (not
the current drops to 0.4 A during normal depressed) relay coil A is excited as soon as the start
operation. Closing and opening times of the but-
main contactor are respectively 65 ms and Figure 20.21
130 ms. Special self-protected starter rated at 40 hp, 460 V, 60
Fig. 20.21 shows a special combination starter Hz. In addition to a short-circuit capability of 42 kA at
460 V, it features adjustable thermal and magnetic trip
that can be reset remotely following a short-
settings. Overall dimensions: 243 mm high, 90 mm
circuit. Its distinguishing feature is that it is
wide, 179 mm deep.
programmable and requires no fuses. The
(Courtesy of Telemecanique, Groupe Schneider)
sophisticated contactor is designed to inten-upt
short-circuit currents in less than 3 ms, which is
ton is depressed. Sealing contact Ax
comparable to that offered by HRC
in the main contactor closes and so
1 the motor will continue to turn after
the start button is released. Thus,
the control circuit operates in the
same way as in Fig. 20.16b.
Suppose now that the motor is
stopped and we depress the jog button.
1 This closes contacts 3, 4 and relay
coil A is excited. Contact Ax closes, to weld together. Repeated

but contacts l , 2 are now open and jogging will also overheat the
the closure of Ax has no effect. The motor. When jogging is
motor will pick up speed so long as required, the contactor is
the jog button is depressed. However, usually selected to be one NEMA
when it is released, coil A will size larger than that for
become de-energized and contactor A normal duty.
will drop out, causing Ax to open.
Thus, when contacts l , 2 are again
bridged, the motor will come to a 20.9 Reversing the
halt. Thus, by momentarily depressing direction of
the jog button we can briefly apply
power to the motor. rotation
Jogging imposes severe duty on We can reverse the direction of
the main power contacts A because rotation of a 3-phase motor by
they continually make and break interchanging any two lines. This
currents that are 6 times greater can be done by using two magnetic
than normal. contactors A and B and a manual 3-
position cam switch as shown in
Fig. 20.23. When contactor A is
stop start
closed, lines L l , L2, and L3 are
8 connected to terminals A, B, C of
the motor. But when contactor B is
closed, the same lines are
1 ostl connected to motor terminals C, B,
O stop
A O jog A.
In the forward direction, the
Figure 20.22 cam switch engages contact l ,
Control circuit which energizes relay coil A,
and pushbutton station for start-stop job operation. causing contactor A to close.
Terminals 8, L3 correspond to terminals 8, L3 in **
Fig. 20.13.
A magnetic contact has an estimated
It is estimated that each nnechanical life of about 20 million
open/close cycles, but the electrical
impulse corresponds to 30
contacts should be replaced after 3
normal start-stop operations. million nornv,ll cycles. The contacts
Thus, a contactor that can and relay coils may be designated by
normally start and stop a motor any appropriate letters. Thus, the
3 million times, can only jog letters F and R are often used to
the motor 100 000 times, designate .fbrward and reverse
operating co•nponents. In this book we
because the contacts have to be
have adopted the letters A and B
replaced. * Furthermore, mainly for reasons of continuity from
jogging should not be repeated one circuit to the next.
too quickly, because the
intense heat of the breaking
arc may cause the main contacts
BASICS OF INDUSTRIAL MOTOR CONTROL 457
disconnecting switch to
be
c
cam
U switch 1 forward
emergency
B reverse pushbutton 2
Figure 20.23a
Simplified schematic diagram of a reversible magnetic starter.
Figure 20.23b
Three-position cam switch in Fig.
20.23a.
( Courtesy of Siemens)
To reverse the rotation, we move
the cam switch to position 2.
However, in doing so, we have to
move past the off position (0).
Consequently, it is impossible to
energize coils A and B
simultaneously. Occasionally,
however, a mechanical defect may
prevent a contactor from dropping
out, even after its relay coil is
de-energized. This is a serious
situation,
Figure 20.23c
Emergency stop pushbutton jn Fig. 20.23a.
(Courtesy of Square D)
because when the other contactor
closes, a shortcircuit results across
the line. The short-circuit current
could easily be 50 to 500 times
greater than normal, and both
contactors could be severely damaged.
Figure 20.24a
To eliminate this danger, the
contactors are mounted side by side Simplified schematic diagram of a starter with plugging control.
closed
and mechanically interlocked, so as to at the same time. The interlock is a simple 2. The start
make it physically impossible for bothsteel bar, pivoted at the center, whose extremities are one NC co
ed to the movable armature of each contactor. contact 3, 4 opens before contact l , 2 closes. Several
During an emergency, pushbutton U, equipped 3. Contactor B is used to stop the motor. types It is of zero-
th a large red bull's-eye, can be used to stop the identical to contactor A, having 2 auxiliary speed switches
otor (Fig. 20.23c). In practice, operators find it contacts Bxl and Be in addition to the 3are main on the
asier to hit a large button than to turn a cam switch contacts B. market and
the off position. 4. The stop pushbutton is identical to the Fig. start 20.24b
pushbutton. Thus, when it is depressedshows one that
contact operates on
0.10 Plugging 7, 8 opens before contact 5, 6 closes. the principle
of an
5. Contact F-C of the zero-speed switch is normally
induction
e have already seen that an induction motor can be open, but it closes as soon as the motor turns in
motor. It
ought to a rapid stop by reversing two of the lines the forward direction. This prepares the plugging
consists of a
ection 14.8). However, to prevent the motor from circuit for the eventual operation of coil B.
small
nning in reverse, a zero-speed switch must open the 6. Contacts Axl and Figure
Bxl are sealing contacts so
permanent
e as soon as the machine has come to rest. The cir- 20.24c
that pushbuttons A and B have only to magnet be rotor
it of Fig. 20.24a shows the basic elements of such Zero-speed
pressed momentarily to start or stop theN, S and a
motor. switch,
bronze ring or
plugging circuit. The circuit operates as follows: Contacts Ax2 and centrifugal
Bx2 are electrical interlocks
cup supported
7. to type.
( Court
on bearings,
Contactor A is used to start the motor. In addi- prevent the relay coils A and B from being which ex- is free
esy of
tion to its 3 main contacts A, it has 2 small aux- cited at the same time. Thus, when theto
Hubbe/) motor pivot
is relay between
iliary contacts Axl and Ax2. running, contact
coil Ax2 is open.
B stationary
Consequently,
dra contacts F and
g cannot
bearing R. The
cu become
p excited permanent
by magnet is
depressi coupled to the
ng shaft of the
pushbutt main motor, As
on B soon as the
Figure until motor turns
20.24b such clockwise, the
Typical zero- time as permanent
speed switch contacto magnet drags
for use jn Fig. r A has the ring along
20.24a. dropped in the same
out, direction,
causing thereby
contact closing
drag cup contacts F-C.
A xo to
reclose. When the motor
stops turning,
the brass ring
returns to 20.1 1 applications by employing

the off , a motor an
position. Reduced- cannot be autotransforme
Because of voltage directly r. In reducing
its function connected to the voltage,
and shape, starting the line we recall the
the ring is Some because the following.
often called industrial starting
l . The
a drag-cup. loads have to current is
locked-
Fig. be started too high. In
rotor
20.24c shows very all these
current is
another gradually. cases we
proportiona
zero-speed Examples are have to
l to the
switch that coil winders, reduce the
voltage:
operates on printing voltage
reducing
the presses, applied to
the voltage
principle of conveyor the motor
by half
centrifugal belts, and either by
reduces the
force. machines that connecting
current by
process resistors
half.
fragile (or
products. In reactors) in 2. The
other series with locked-
industrial the line or rotor
torque is
proporti consists of first, but gradually following circuit

onal to placing three diminishes as the elements:
the resistors in motor picks up
square series with the speed and the magnetic
of the motor during current falls. contactor relay
the start-up Consequently, the coils
voltage:
period (Fig. voltage across the
reducing Ax:
20.25a). motor terminals
the Contactor A auxiliary
voltage increases with
closes first contact
by half speed, and so the
and Figure 20.25b associated with
electrical and
reduces Control circuit of Fig. A time-delay
mechanical shock
the 20.25a. relay that closes
is negligible when
torque the circuit of
full voltage is
by a coil B after a
when the motor has finally applied
factor preset interval
nearly reached (closure of
of four. of time
synchronous speed, a contactor B). The
second contact B resistors are short-
20.12 short-circuits the circuited after a
resistors. This method delay that depends
Primary gives a very smooth upon the setting of
resistance start with complete a time-delay relay.
absence of mechanical The schematic
starting shock. The voltage control diagram
Primary drop across the (Fig. 20.25b)
resistance resistors is high at reveals the
starting
disconnecting
switch
Figure 20.25a
Simplified schematic diagram of the power section of a reduced-voltage primary resistor stator.
20.25b. In operation of the reduced to are chosen so

such circuit. 0.65 pu. that the
cases, it is How are the locked-rotor
better to starting voltage across
Fi g . 20.26a
add an characteristics the stator is
auxiliary affected when shows the
torque- 0.65 pu. The
relay resistors are locked-rotor
havin g
inserted in series speed
torque is,
more with the
therefore,
robust stator?
(0.65)- 0.42
contacts.
Thus, in pu or only 42
Fig. percent of full-
20.25c, load torque.
the This means
purpose of that the motor
auxiliary must be
relay RA started at light
speed
is to carry load.
p.u.
the Fig. 20.26b
exciting curve I shows the
currents of when full current versus
relay coils o
voltage is speed curve I
A and B. applied to when full
Note that a typical 3- voltage is
the start applied to the
phase,
pushbutto stator. Curve 2
1800 r/min
n contacts shows the
induction
carry only current when
the motor. the resistors are
Figure 20.26a Correspon
exciting in the circuit.
Typical torque- ding curve
current of When the
speed curves of 2 shows
relay coils speed reaches
RA and a 3-phase what about 1700
RT. Other squirrel-cage happens r/min, the
circuit induction when resistors are
componen motor: (1) full- resistors short-circuited.
ts are voltage are The current
straightfor starting; (2) jumps from
inserted in
ward, and primary
series with about
the reader should resistance
the line. 1.8 pu to 2.5
have no difficulty starting with
The
pu, which is a
in analyzing the voltage very moderate
resistors
jump.
Example rotor resistance 5

starting with
20-2 conditions X
voltage reduced
b. The apparent to 0.65 pu. 4
A 150 kW power 6
(200 hp). absorbed by 0
460 V, 3- the motor =
phase 3520 when the c. The
2
r/min, 60 resistors are in apparent
9
Hz the circuit power
9
induction drawn from
V
motor has the line,
with the The current
a locked-
resistors in drawn by the
rotor
the circuit motor decreases
torque of
600 and a d. The locked- in proportion to
rotor the voltage:
locked-
rotor torque
current of o
developed
by the 0.65 X 1400
1400 A.
Three 40 motor 910 A The
0
resistors Solution apparent
are 80 a. At full voltage
power
connected 0 the locked-
in series rotor apparent drawn by
with the 12 power is
00 the motor
line so as
16 is
to reduce 00
the voltage 18 = 1 3 El
across the 00
1400 =
motor to r/
mi
b. The voltage 1
n
Calculate across the
a. The sp motor at 0.65 3
apparent ee pu is
d
power E x
absorbed 2
Figure 20.26b
by the = 9
Typical current-
motor speed curves of a 3- 9
under full- phase squirrel-cage 0
voltage, induction motor: (1 ) . x
full-voltage starting;
locked- (2) primary 6 9
1 only 724 kVA/1114 We will solve this The reactive power

0 kVA = 65% of the problem by absorbed by the
apparent power considering active motor is
under full-voltage and reactive
c. The apparent powers and using
conditions.
power drawn the power triangle 441 kvar
d. The torque varies
from the line is method. The The resistors
as the square of apparent power
the voltage: can only
drawn by the
absorb active
= T = motor at reduced
power in the
voltage is
0.6 circuit.
N 5 2x = 471 kVA Consequently
: 600 (from Example , the reactive
= 0.42 x 20-2) power
3 600 supplied by
The the line must
= 252
x corresponding be equal to
(—186 ft.lbf)
apparent power that
4 The results of these drawn by the absorbed by
6 calculations are the motor:
0 summarized in Fig.
= 724 kVA
20.27. QL = 441 kvar
(from Example
x 20-2) The active power
Example 20-3
supplied by the line
9 The active power
is
1 In Example 20-2, if drawn by the
0 the locked-rotor motor is PL
power factor of the
= = sm V
motor alone is 0.35,
724 e = 471 X 0.35
calculate the value s
kV =
of the series i
A
= 724 kVA Sm = 471 kVA = 724 kVA
ser ies = 574 kW P = 165 kW
sm = 471 kVA resistors
460 V 299 v QL = 441 k var = 441 kvar
locked rotor
910 A 910 A 460 v locked rotor
resistors 299 v
Figure 20.27 910 A 910 A

See Example 20-2. Figure 20.28
See Example 20-3. -
Thus, resistors and the 165 Q
percentagewise power they kW
i
, the apparent dissipate.
power is Solution
= Example 20- This is triangle

2) an method in
The value of each interestin solving a
V g relatively
r
7 e example difTicult
s of the problem. The
2
i usefulnes results are
4 s s of the summarized
2 t power in Fig. 20.28.
o 20.13 Autotransformer starting
-
r Compared to a resistance starter, the advantage
4 of an autotransformer starter is that for a given
i torque it draws a much lower line current. The
4
s disadvantage is that autotransformers cost more,
1 and the transition from reduced-voltage to full-
p voltage is not quite as smooth.
Autotransformers usually have taps to give
5 = output voltages of 0.8, 0.65, and 0.5 pu. The
7 corresponding starting torques are respectively
1 0.64, 0.42, and 0.25 of the full-voltage starting
4 2 torque. Furthermore, the starting currents on
R the line side are also reduced to 0.64, 0.42, and
136 000 = 0.25 of the fullvoltage locked-rotor current.
k Fig. 20.29 shows a starter using two
R
W autotransformers connected in open delta. A
simplified circuit diagram of' such a starter is
The active power The three given in Fig. 20.30. It has two contactors A and B.
absorbed by the resistors must Contactor A has five NO contacts A and one
three resistors is therefore small NO contact Ax. This
each have a contactor is in operation only during the brief pe- Fig
resistance of riod when the motor is starting up. Red
574 - 165
0.164 0 and a hp,
409 short-term 575
The active power rating of 136 (Co
per resistor is kW. The
physical size 1
P = PR/3 of these B 80
409/3 = resistors is 2
136 kW much smaller disconnecting
switch
The current in than if they
were designed 3 start -L 80 5
each resistor is
for continuous
I = 910 A duty. RTI
(from
This transient surge is case is 0.65 pu.

hard on the contacts The reader will
and also produces a note that the
mechanical shock. For locked-rotor
this reason, we torques are
interlocksometimes
—H employ identical, but the
more elaborate circuits locked-rotor line
in which the motor is current is much
never completely lower using an
disconnected from the autotransformer
Figure 20.30 line. (2.7 versus 4.2
Simplified schematic diagram of an pu).
autotransformer starter. However,
Contactor B has 3 appears across the when the motor
NO contacts B. It is in motor terminals. reaches about 90
service while the A few seconds later, percent of
motor is running. contact RT2 in series synchronous
speed, resistance
The with coil A opens,
starting produces
autotransformers are causing contactor A to
a higher torque
set on the 65 percent open. At the same
because the
tap. The time-delay time, contact RT3 terminal voltage is
relay RT possesses causes contactor B to slightly higher
three contacts RTI, close. Thus, contactor than the 65
RT2, RT3. The contact A drops out, followed Figure 20.31 a percent value that
RTI in parallel with almost immediately by Typical reduced existed at the
the start button closes the closure of voltage (0.65 pu) moment of start-
as soon as coil RT is contactor B. This torque-speed curves of up. On the other
a 3-phase squirrel-cage hand, the line
energized. The other action applies full induction motor: (2)
two contacts RT 2, voltage to the motor primary resistance current at all
RT3 operate after a and simultaneously starting; (3) speeds is smaller
delay that depends disconnects the autotransformer when using an
starting. autotransformer.
upon the RT relay autotransformer from
Figs. 20.3 l a Because the
setting. Contactors A the line.
and 20.31b autotransformers
and B are In transferring from
compare the operate for very
mechanically contactor A to
torque and line short periods,
interlocked to prevent contactor B, the motor
current when they can be
them from closing is disconnected from
autotransformer wound with
simultaneously. the line for a fraction
starting (3) and much smaller
Contactor A closes of a second. This
resistance wire than
as soon as the start creates a problem
starting (2) is continuously
button is depressed. because when
used. The rated devices.
This excites the contactor B closes, a
locked-rotor This enables us
autotransformer and large transient current
voltage in each to drastically
reduced voltage is drawn from the line.
reduce the size, supplied by the 460 a. The voltage negligible

weight, and cost V line across the (Section 12.
of these motor is l).
components. E = 0.65 X Consequently
p.u.
,
6 460 = 299
Example 20-4 = 471 kVA
V
The current c. The current
A 200 hp (150
drawn by the drawn from
kW), 460 V, 3-
4 motor is the line is
phase, 3520 2
r/min, 60 Hz 1 = 0.65 X 1400
induction motor = 910 A =
has a locked- o 400 800 The apparent 4
rotor torque of 1200 1600 1800 power drawn 7
600 and a speed
by the motor 1
locked-rotor is 0
current of 1400 Figure 20.31b 0
A (same motor Typical reduced 0/
as in Example voltage (0.65 pu)
current-speed 3 (
20-2). Two curves of a 3- 1
x
autotransformers phase squirrel- .
cage induction 2
, connected in 7
open delta, and motor: (2) 9
primary 9 3
having a 65 resistance x
percent tap, are starting; (3) x
autotransformer 9 4
employed to
starting. 1 6
provide reduced-
c. The current 0 0
voltage starting.
supplied by = 471 k VA )
Calculate the 460 V = 592
b. The apparent
a. The apparent power line A
power
absorbed by the d. The locked- Note that this
supplied by
motor rotor torque current is
the line is
b. considerably
equal to that
The smaller than
absorbed by
the motor the line
current (910
2 because the
A) with
active and
resistance
reactive starting.
3
power d. The locked-
consumed by rotor torque
the varies as the
apparent power autotransform square of the
Solution
ers is
motor 20.14 Other B can be arranged for

voltage: part-winding starting.
starting Contactor A closes
T = 0.65 2 x 600
0.42 x 600 methods first, thus energizing
= In addition to resistors windings l , 2, 3.
2 and autotransformers, Shortly after, contactor
5 several other methods B closes, bringing
2 are employed to limit windings 7, 8, 9 in
the current and torque parallel with windings
when starting l , 2, 3.
s L 471 k VA 471 k
460 v 299 v
A
induction motors.
VA locked rotor
Some only require a
change in the stator
592 A winding connections.
910 The part-winding
au starting method can be
tot
ra
used when the
ns induction motor has
fo two identical 3-phase
rm
er
windings that operate
in parallel when the
Figure 20.32 motor is running.
See Example 20- During the starting
4. phase, only one of Figure 20.33
these 3-phase Part-winding starting of
The results of
windings is used. As a an induction motor.
these calculations
result, the impedance
are summarized in
is higher than if the
Fig. 20.32. It is
two windings were
worthwhile
connected in parallel.
comparing them
After the motor has
with the results in
picked up speed, the
Fig. 20.27.
second 3-phase
winding is brought
into service so that the
two windings operate
in parallel. Fig. 20.33
shows how two 3-pole
contactors A and
46
1
T that
I jum
F pers
S J l ,
F J 2,
J 3,
forward
stop J4
are
reverse
also
5 requ
ired
FS to
contact forward stop reverse

a.
reverse Q
1 b.
forward x
2 c.
x
3 x
a
4 x
5 x x
The com
3- plete
phasthe
e conn
line ectio
and ns.
mot The
or read
are er
connshou
ecte ld
d toanal
the yze
appr the
opri circu
ate it
cam-conn
swit ectio
ch ns
termand
inalsresul
. ting
Notecurr
BASICS OF INDUSTRIAL MOTOR
CONTROL
ent ches
floware
for desi
eachgned
positto
ion carr
of y
the seve
swit ral
ch. hun
For dred
exa amp
mpleeres,
, but
whe we
n theofte
swit
n
ch is
pref
in
er to
the
forwuse
ard mag
positnetic
ion, cont
cont actor
acts s to
2, 4,hand
5 arele
clos large
ed curr
and ents.
L lIn
is such
conncase
ecte s a
d tosmal
T l ,l
L2 cam
to Tswit
2, ch is
and empl
oyed
to
cont
ome rol
cam the
swit
relaydevi
coilsces
of we
the have
cont cove
actorred
s. in
Verythis
elab chap
orateter
cont are
rol used
sche thro
mes ugh
can out
be the
desi indu
gnedstry.
with Ho
multwev
iconter,
act with
cam the
swit adve
ches.nt of
com
20.pute
rs, it
16 is
now
Co poss
mpible
to
utesim
rs ulat
e the
an beha
d vior
of
co man
y
ntr rela
ols y
coils
The
and
cont
rela
rol
y
CONTROL
cont d, a
acts.mon
Furt itor,
her and
mor a
e, com
the pute
con r.
nect Thu
ions s.
bet inste
wee ad
n of
thes usin
e g
devi real
ces rela
can ys,
also cont
be acts,
sim and
ulat time
ed. -
As adela
resu y
lt, itdash
is pots,
posswe
ible sim
to ply
mak prog
e rcun
very thes
com e
plex devi
cont ces
rol (and
circ their
uits wiri
by ng)
sim on a
ply com
usin pute
g ar.
key The
boar com
pute TRI
rs
used C
for DR
this
purpIVE
ose S
are
calle
20.17
d
ProgFu
ram
mab nd
le am
Logi
c ent
Con
troll
als
ers of
(PL
Cs). ele
Theictri
r
consc
tructdri
ion
and ves
basi
c
*
prin In
this
cipl
chap
e ofter
oper we
atio have
n seen
are the
covebasic
red contr
in ol
Cha equi
pter pme
nt
31.
that
is
EL used
to
EC start
and
CONTROL
stop .
indu (IE
EE
ction Sta
moto nda
rs. rd
Dic
tio
An nar
y
o/'
Ele
ctri
cal
and
Ele
ctr
oni
cs
Te
nns
)
ge
F
E
I
I
A
D
Q
T
R
T
4
rstan gene
d the
basic
princ
iples
of
varia
ble
spee
d
F contr
T ol,
we
will
first
sho
w
how
varia
ble
freq
uenc
y
affec
ts
F the
T
beha
I vior
varyiof a
ng squir
the rel-
voltacage
ge indu
and ction
frequmoto
encyr.
appli
ed to
the
stato
r.
o
bette
r
unde
CONTROL
20.19 uenc
y
Sh appl
apeied
to
of the
the stato
tor r.We
quealrea
- dy kno
spew
ed that
if
curthe
ve freq
The uenc
torq y is
ue- fixe
spee d,
d the
curv torq
e ofue
a 3-vari
phases as
e the
squi squa
rrel- re of
cagethe
indu appl
ctio ied
n volt
mot age.
or We
depealso
nds kno
upo w
n that
the the
volt sync
age hron
and ous
freq spee
d
depesam
nds e
on prop
the ortio
freq n so
uencas to
y. mai
The ntai
quesn a
tion cons
now tant
ariseflux
s, in
how the
is air
the gap.
torq Thu
ue- s,
spee whe
d n
curv the
e freq
affe uenc
cted y is
whe dou
n bled
both , the
the stato
volt' r
age volt
and age
freq is
uencdou
y bled
are .
vari Und
ed? er
In thes
prac e
tice, cond
they ition
are s,
vari the
ed shap
in e of
the the
CONTROL
torq g
ue- the
spee spee
d d
curv axis
e shift
rem s
ains with
the the
sam freq
e, uenc
but y.
its V
positF
ion I
E
alon
2100 180
aaua
Fi
gu
re
20
.3
9
To
rq
ue
-
sp
ee
d
cu
rv
e
of
a
15
hp,
46
0
V,
60
Hz
,
3-
ph
as
e
sq
uir
rel
-
ca
ge
in
du
cti
on
m
ot
or.
46
5
N.
m
11
5
V,
15
Hz
46
0
V,
CONTROL
60
Hz
69
0
V,
90
Hz
2100 1800 1500
Fi
g
ur
e
2
0.
4
0
To
rq
ue
-
sp
ee
d
cu
rv
e
at
thr
ee
dif
fer
ent
fre
qu
en
cie
s
an
d
vo
lta
ge
s.
N.m
160
80
1200 600 1200
80
160 r/min
B
ec
au
se
th
e
sh
ap
e
of
th
e
to
rq
ue
-
sp
CONTROL
ee
d
cu
rv
e
is
th
e
sa
m
e
at
all
fr
eq
ue
nc
ie
s,
it
fo
llo
w
s
th
at
th
e
to
rq
ue
de
ve
lo
pe
d
by
an
in
du
cti
on
m
ot
or
is the same w
slip speed (i
the same.
Exampl
A standard 3
hp, 575 V
r/min, 60
NEMA cla
squirrel-cage
induction
develops a to
1 10 at a sp
1440 r/min.
motor is exci
frequency of
calculate
following:
a. The r
voltage
maintain
same flux
machine
b. The new s
a torque o
Soluti
on
Figure 20.41
Stator excited by
shape. Current c
the stator while le
tor develops a sym
creases with incr

both directions, a
ure, the dc curren
duce the rated bre
The for the

slip same
speedtorque,
is theirrespe
samective
CONTROL
of the
ed
freque
cha
ncy. ract
The eris
synchr
tic
onousof
speedan
at 25ind
Hz isucti
on
mot
5/60)
or
is a
1800V-
sha
ped
cur
ve
hav
390 ing
r/m a
in min
imu
m
20 val
ue
.2 at
0 syn
chr
C ono
ur us
spe
re ed.
nt- The
min
sp imu
ee m curr
d ent
cu isequ
rv al
to
es the
The ma
curr gne
ent- tizi
spe ng
curr cur
ent ren
nee t-
ded spe
to ed
crea
cur
te
ve
the
of
flux
in the
the 15
mac hp,
hin 460
e. V,
Bec 60
aus Hz
e squ
the irre
stat l-
or cag
flux e
is
ind
kep
ucti
t
con on
stan mo
t, tor
the me
ma nti
gne one
tizi d
ng pre
curr vio
ent usl
is y.
the We
sam
hav
e at
e
all
spe
plo
eds. tted
the
ig. eff
20. ecti
42 ve
sho val
ws ues
the of
cur
CONTROL
ren A
t s in
for the
all cas
spe e of
eds the
; tor
con que
seq -
uen spe
tly, ed
the cur
cur ve.
ren it
t is can
alw be
ays sho
pos wn
itiv that
e. if
Th the
e stat
loc or
ked flu
- x is
rot hel
or d
cur con
ren sta
t is nt,
120 the
A
N
and
c
the w
cor S
res I
pon N
din
g
tor
que
is
80
N•
m.
F
T
U
S
W
A
600 300
r/min.
=
T
The
T
E
T
A
F
E
i
n
m
o
v
i
n
g
a
l
o
n
g
t
h
e
c
u
r
v
e
f
r
o
m
p
o
i
CONTROL
n
t
2
t
o
p
o
i
n
t
3
,
e
n
-
2
0
-
I
l
R
e
f
e
r
ri
n
g
t
o
F
i
g
.
2
0
.
3
9
,
c
a
l
c
u
l
a
t
e
t
h
e
m
e
e
r
g
y
i
s
r
e
t
u
r
n
e
d
t
o
t
h
e
a
c
li
n
e
,
b
e
c
a
u
s
e
t
h
e
m
o
t
o
r
a
c
t
CONTROL
s
c
h
a
n
i
c
a
l
p
o
w
e
r
[
h
p
]
o
f
t
h
e
m
o
t
o
r
w
h
e
n
it
a
s
a
n
a
s
y
n
c
h
r
o
n
o
u
s
g
e
n
e
r
a
t
o
r
d
u
ri
n
g
t
h
i
s
i
n
t
e
r
v
a
l.
r
u
n
s
a
t
4
5
0
r/
m
i
n
.
T
he
ab
ili
ty
CONTROL
to
de
ve
lo
p
a
hi
gh
to
rq
ue
fr
o
m
ze
ro
to
20
-
12
A
st
an
da
rd
3-
ph
as
e,
4-
po
le
sq
ui
rr
el
-
ca
ge
fu
ll
sp
ee
d,
to
ge
th
er
wi
th
th
e
ec
on
o
m
y
of
re
ge
ne
ra
-
in
du
cti
on
m
ot
CONTROL
or
is
ra
te
d
at
20
8
V,
60
H
z.
ti
ve
br
ak
in
g,
is
th
e
m
ai
n
re
as
on
w
hy
fr
eq
ue
nc
y-
W
e
w
an
t
th
e
m
ot
or
to
tu
rn
at
a
no
-
lo
ad
co
nt
ro
lle
d
in
du
cti
on
m
ot
or
dr
iv
es
ar
CONTROL
e
be
co
m
in
g
so
sp
ee
d
of
ab
ou
t
22
5
r/
m
in
w
hi
le
m
ai
nt
ai
np
op
ul
ar
.
T
he
se
el
ec
tr
on
ic
all
y-
co
nt
ro
lle
d
dr
iv
es
ar
e
in
g
th
e
sa
m
e
fl
ux
in
th
e
ai
r
ga
p.
C
al
CONTROL
cu
lat
e
co
ve
re
d
in
C
ha
pt
er
23
.
th
e
re
qu
ir
ed
vo
lta
ge
an
d
fr
eq
ue
nc
y
to
be
ap
pl
ie
d
to
th
e
st
at
or
.
Q
u
e
st
i
o
n
s
a
n
d
P
r
o
b
l
e
m
s
2
0-
13
R
ef
CONTROL
er
ri
ng
to
Fi
g.
20
.4
2,
w
ha
t
is
th
e
cu
rP
ra
cti
ca
l
le
ve
l
re
nt
in
th
e
st
at
or
un
de
r
th
e
fo
ll
o
wi
ng
20-I
N
a
m
e
fo
ur
ty
pe
s
of
ci
rc
ui
t
di
ag
ra
m
s
an
d
co
nd
iti
on
s,
kn
o
wi
ng
th
at
th
e
st
at
or
is
en
de
sc
ri
be
th
e
CONTROL
pu
rp
os
e
of
ea
ch
.
er
gi
ze
d
at
46
0
V,
60
H
z?
a.
M
ac
hi
ne
ru
nn
in
g
as
a
m
ot
or
at
16
50
r/
m
in
20-2
W
i
t
h
o
u
t
r
e
f
e
r
r
i
n
g
t
o
t
h
e
t
e
x
t
,
d
e
s
c
r
i
b
e
t
h
e
a
n
d
d
e
v
e
l
o
CONTROL
p
i
n
g
t
o
r
q
u
e
o
f
1
0
0
o
p
e
r
a
t
i
o
n
o
f
t
h
e
s
t
a
r
t
e
r
s
h
o
w
n
i
n
F
i
g
.
b
.
M
a
c
h
i
n
e
r
u
n
n
i
n
g
a
s
b
r
a
k
e
a
t
3
0
(
)
CONTROL
r
/
m
i
n
2
0.
16
b,
an
d
sta
te
th
e
us
e
of
ea
ch
co
m
po
ne
nt.
c.
M
ac
hi
ne
dri
ve
n
as
an
as
yn
ch
ro
no
us
ge
ne
ra
20
-3
Gi
ve
th
e
sy
m
bo
ls
fo
ra
N
O
an
d
a
N
C
co
n-
tor
at
a
tor
qu
e
of
12
CONTROL
0
ta
ct,
an
d
fo
ra
th
er
m
al
rel
ay
.
20
-
14
St
at
e
in
w
hi
ch
qu
ad
ra
nt
sa
m
ac
hi
ne
op
er
at
es
20
-4
Id
en
tif
y
all
th
e
co
m
po
ne
nt
s
sh
o
w
n
in
Fi
g.
As
a
br
ak
e
20
.2
3a
us
in
g
th
e
eq
ui
p
m
en
CONTROL
t
lis
t
gi
ve
n
in
As
a
m
ot
or
2()
A.
W
he
re
are
co
nta
ct
T
an
d
coi
l
As
a
ge
ne
rat
or
Table
A
s
i
t
u
a
t
e
d
p
h
y
s
i
c
a
l
l
y
?
2
0
-
1
5
m
a
c
h
i
n
e
i
s
t
u
r
CONTROL
n
i
n
g
c
l
o
c
k
w
i
s
e
i
n
q
u
a
d
2
0
-
5
I
f
t
h
e
s
t
a
r
t
a
n
d
s
t
o
p
p
u
s
h
b
u
t
t
o
n
s
i
n
F
i
g
.
r
a
n
CONTROL
t
3
.
D
o
e
s
i
t
d
e
v
e
l
o
p
c
l
o
c
k
w
i
s
e
o
r
2
(
)
.
2
4
a
a
r
e
p
u
s
h
e
d
s
i
m
u
l
t
a
n
e
o
u
s
l
y
,
w
CONTROL
h
a
t
c
o
u
n
t
e
r
c
l
o
c
k
w
i
s
e
t
o
r
q
u
e
?
w
i
l
l
h
a
p
p
e
n
.
20.6 R
e
f
e
r
r
i
n
g
t
o
F
i
g
.
2
0
.
1
4
,
i
f
c
o
n
t
a
c
t
A
x
CONTROL
i
n
p
a
r
a
l
l
e
l
w
i
t
h
t
h
e
s
t
a
r
t
p
u
s
h
b
u
t
t
o
n
w
e
r
e
r
e
m
o
v
e
d
,
w
h
a
t
e
f
f
e
c
t
w
o
u
l
d
i
t
h
a
v
e
o
n
t
h
e
o
p
e
r
a
CONTROL
t
i
o
n
o
f
t
h
e
s
t
a
r
t
e
r
?
20.7 I
f
s
h
o
r
t
-
c
i
r
c
u
i
t
o
c
c
u
r
s
i
n
m
o
t
o
r
o
f
F
i
g
.
20.
14,
whic
h
devic
e will
open
the
circui
t?
20-8 A
p
a
r
t
i
a
l
s
h
o
r
t
-
c
i
r
CONTROL
c
u
i
t
b
e
t
w
e
e
n
t
h
e
t
u
r
n
s
o
f
t
h
e
s
t
a
t
o
r
w
i
n
d
i
n
g
o
f
m
o
t
o
r
i
n
F
i
g
.
2
0
.
1
4
p
r
o
d
u
c
e
s
5
0
%
i
n
c
r
e
a
s
e
i
n
CONTROL
t
h
e
l
i
n
e
c
u
r
r
e
n
t
o
f
o
n
e
p
h
a
s
e
.
W
h
i
c
h
d
e
v
i
c
e
w
i
l
l
s
h
u
t
d
o
w
n
t
h
e
m
o
t
o
r
'
?
20— 9
U
n
d
e
r
w
h
a
t
c
i
r
c
u
m
s
t
a
n
c
e
s
CONTROL
i
s
r
e
d
u
c
e
d
v
o
l
t
a
g
e
s
t
a
r
t
i
n
g
r
e
q
u
i
r
e
d
?
20-10
R
e
f
e
r
r
i
n
g
t
o
F
i
g
.
2
0
.
3
9
,
i
n
w
h
i
c
h
q
u
a
d
r
a
n
t
s
d
o
t
h
e
f
o
CONTROL
l
l
o
w
i
n
g
t
o
r
q
u
e
-
s
p
e
e
d
o
p
e
r
a
t
i
n
g
p
o
i
n
t
s
o
c
c
u
r
'
?
a. +
16
50
r/
mi
n,
+
10
0
N.
m
b. +3
15
()
r/
m:
n,•
-
IO
O
In
te
r
m
ed
iat
e
le
ve
l
20-16 A
th
er
m
al
re
la
y
ha
vi
ng
th
e
tri
pp
in
CONTROL
g
cu
rv
eo
iv
en
in
Fi
g.
20
.
17
ha
s
to
pr
ot
ec
ta
40
hp
,
57
5
V,
3-
ph
as
e,
72
0
r/
m
in
in
du
cti
on
m
ot
or
ha
vi
ng
a
no
m
in
al
cu
rr
en
t
ra
ti
ng
of
40
A.
If
th
e
re
la
y
is
se
t
to
40
A,
ho
w
lo
ng
wi
ll
it
ta
ke
to
tri
p
if
th
e
m
ot
or
cu
rr
CONTROL
en
t
is
b. 240
A?
20-17 a.
If
the
co
ntr
ol
cir
cui
t
of
Fi
g.
20.
22
is
us
ed
in
pla
ce
of
tha
t
sh
ow
n
in
Fi
g.
20.
14,
sh
ow
tha
t
the
m
ot
or
wi
ll
sta
rt
an
d
co
nti
nu
e
to
ru
n
if
we
m
o
me
nta
ril
y
pr
ess
the
sta
rt
bu
tto
n.
b.
Sho
w
that
if
we
pre
ss
the
jog
butt
on,
the
mot
or
onl
y
run
s
for
as
lon
g as
the
butt
on
is
dep
ress
ed.
20-1 8 A
m
ag
CONTROL
ne
tic
co
nt
ac
to
r
ca
n
m
ak
e
3
m
ill
io
n
no
r
m
al
ci
rc
ui
t
in
te
rr
up
ti
on
s
be
fo
re
its
co
nt
ac
ts
ne
ed
to
be
re
pl
ac
ed
.
If
an
op
er
at
or
jo
gs
th
e
m
ot
or
so
th
at
it
st
ar
ts
an
d
st
op
s
469
onceassumi
per ng the
minute
operat
, after
or
approx
works
imatel
an 8-
y howhour
many day?
workin
20.19 ab.
g days If
will the
the mot
contac or is
ts have runn
to be ing
replac nor
ed, mall
CONTROL
c. As a
gene
rator
at
2550
r/mi
n
20.24 I
20.25 R
the
machi
ne so
that it
runs as
a
relativ
ely
high-
20.20 a efficie
Withncy
the
motor;
motor
runnia. At a
ng, spee
expla d of
120(
)
what
r/mi
happe
n,
deve
when
lopi
the
ng a
stop
torq
butto
ue
n is
of
depre 1()0
ssed.
20.21 R b. At a
20.22 A spee
20.23 R
a. d of
2400
r/mi
n,
deve
lopi
ng a
b. torq
ue
of
60
20.26 R
20.27 a r/mi
b. Cann
d. The
start
ing
torq
ue
[ft•l
bfl
e. Dra
w
the
torq
ue-
spee
d
curv
e
that
20.28 A
a. pass
es
thro
ugh
qua
dran
ts l,
2,
and
4
(see
b.
Fig.
20.3
8)
20.29 a
b.
What
is the
frequ
ency
of the
curre
nt in
the
c. armat
ure
coils
at a
speed
of
30()
CONTROL
r/min'
A
30 a. The
b.
20_31
ELECTRICAL AND ELECTRONIC DRIVES
suddenly blew, causing it to run as a
singlephase motor. As a result, the current
in phases A and B rose to 135 A.
speed of 1 800 r/min. The total moment of What is the maximum possible time
inertia of the rotor and its load is 90 lb•ft2 . it took for the thermal relay to trip the
The speed has to be reduced to a no-load con-
value of 1200 r/min by suddenly changing 64 min
the voltage and frequency applied to the
32 min 16 THERMAL RELAY
min TIME VERSUS TRIPPING CURRENT
Calculate
a. The voltage and frequency required 4 min
b. The initial kinetic energy stored in the
moving parts 3-phase curve
c. The final kinetic energy in the moving parts
d. Is all the lost kinetic energy returned to the
3-phase line'? Explain. 16 s 1 -phase
cu rve
20-32 A 1 5 hp, 460 V, 3-phase, 60 Hz
induction motor has the torque-speed
characteristic
(T iven in Fi o . 20.39.
a. What is the new shape of the curve if we
I
apply 230 V, 60 1-Iz to the stator?
b. Calculate the new breakdown torque [ft•lbfl. s
20.33 In Problem 20-32 calculate the stator 1.5 2 3 4 5 6 7 8 910
voltage needed to reduce the breakdown Multiple of current setting Figure
torque to 60 N•m. 20.45
Industrial application See Problem 20-34.
20.34 A 30 hp, 1780 r/min, 200 V, 3-phase cage
motor driving a compressor is protected by
a thermal relay having the time/current tactor? (The thermal characteristic
characteristic shown in Fig. 20.45. Curve 3 corresponds to cold start conditions.)
relates to normal 3-phase operation, and 20-35 According to the manufacturer's
curve 2 applies when the motor runs
specifications, it is known that the motor
singlephase.
in Problem 20-34 draws a locked-rotor
The plant electrician set the relay at
current of 465 A at 200 V, 3-phase. The
82 A, which corresponds to the rated
perunit starting torque is 2.20.
fullload current of the motor. Under
The motor is started during a
normal operating conditions, a hook-
particularly low voltage-sag in the
on ammeter indicated that the motor
electric utility system. This sag,
draws a current of 71 A from the 200
combined with the line voltage drop
V line.
caused by the large starting current,
Due to a fault on another circuit, the
causes the voltage across the motor
fuse in the distribution panel associated
with phase C of the compressor motor
terminals to fall to 155 V. In turn, the
reduced torque causes the motor to
accelerate very slowly and it doesn't
reach full speed before the thermal relay
trips out.
a. What is the per-unit starting current and per-unit
starting torque under these abnormal conditions?
b. Estimate the time it took for the relay to trip.
20-36 The stator winding of the motor in
Problem 20-34 has a line-to-neutral
resistance of 23 mo.
a. Calculate the stator copper losses when the motor
runs normally on the 3-phase line, driving the
compressor.
b. Calculate the stator copper losses when the motor
runs as a single-phase motor. Does single-phasing
tend to overheat the motor'?
20-37 The holding coil of a 1 3 kW, 230 V,
3-phase 60 Hz contactor has a rating of 120
V. According to the manufacturer's catalog,
when the contactor is in the open
471
position, the coil draws 100 VA at a power factor

of 0.75. In the holding position, the coil absorbs 3
W and 1 1.5 VA.
We want to excite the coil directly off the
230 V line. To achieve this result, calculate the
resistance and power rating of the resistor that
should be connected in series with the coil a)
when the contactor is open and b) when the
contactor is closed.

Basics of Industrial Motor Control: 440 Electrical and Electronic Drives

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Basics of Industrial Motor Control: 440 Electrical and Electronic Drives

Uploaded by

Copyright:

Available Formats

CHAPTER 20

Basics of Industrial Motor

Manual circuit breakers

A can? ,nvitch has a oroup of fixed

BASIC COMPONENTS FOR CONTROL CIRCUITS

Limit switches and special switches

Figure 20.9a SWITCH Limit switch with one NC

closed. Because the relay coil compared to

TABLE 20A GRAPHIC SYMBOLS FOR

• identified by an appropriate letter

1. terminal; connection 2. conductors crossing 3.

motor with commutating winding; permanent magnet dc

physical location of the terminals and even the

600 v thermal overload

Figure 20.14 kind of diagram we

inexpensive. The main basic components: a

line against ranging from 120 V

20.6 Manual Single-phase

20.7 Ax. As can be

Figure 20.16a Three-phase across-the-

disconnecting switch contactor thermal overload relay

the motor against

To stop the motor,

Figure 20.19 Figure 20.20

coil A is excited. Contact Ax closes, to weld together. Repeated

returns to 20.1 1 applications by employing

proporti consists of first, but gradually following circuit

20.25b. In operation of the reduced to are chosen so

Example rotor resistance 5

1 only 724 kVA/1114 We will solve this The reactive power

Figure 20.27 910 A 910 A

= Example 20- This is triangle

This transient surge is case is 0.65 pu.

reduce the size, supplied by the 460 a. The voltage negligible

motor 20.14 Other B can be arranged for

contact forward stop reverse

2100 1800 1500

1200 600 1200

creases with incr

The for the

position, the coil draws 100 VA at a power factor

You might also like