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DESIGN AND CONSTRUCTION OF PRACTICAL MODULE FOR STAR DELTA

STARTER OF AN INDUCTION MOTOR

Conference Paper · May 2023

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 DESIGN AND CONSTRUCTION OF PRACTICAL MODULE FOR STAR DELTA
STARTER OF AN INDUCTION MOTOR

Sani Abdullahi MUHAMMAD

Department of Electrical & Electronics Engineering, School of Technology,
Kano State Polytechnic,
Kano State, Nigeria
Orcid ID:0000-0003-0178-5623

Hamza ABDULLAHI
Department of Electrical & Electronics Engineering, School of Technology,
Kano State Polytechnic,
Kano State, Nigeria

Bello MUHAMMAD
Department of Electrical & Electronics Engineering, School of Technology,
Kano State Polytechnic,
Kano State, Nigeria

Muhammed Mahmud BABANGIDA

Department of Electrical & Electronics Engineering, School of Technology,
Kano State Polytechnic,
Kano State, Nigeria

ABSTRACT

The need for student practical equipment in our institution had led to a number of
alternatives, which have been affordable and available. In response to this, the star delta
starter of induction motor is designed to reduce high starting current and torque. The star
delta starter is designed by three magnetic contactors, an overload relay, timer relay and
circuit breaker. For Starter, a motor must be connected in delta mode position during a
normal run. When induction motor is start in direct online. The motor winding draws a large
amount of current. The starting high current can be reached in 8-10 times of the rated. So,
there is need to control high starting current before starting the motor. Therefore, in a star
connected system line current is equal to phase current but line voltage is equal to the root
three times of phase voltage. For these reasons at first motor is connected to the star system
and it reduce the high starting current. In delta connection, line voltage is equal to phase
voltage and line current is equal to √3 times phase current. In run mode the motor connects
in delta system so that the full voltage applied to the motor. The Starter is made by three
magnetic contactors, timer relay, and a thermal overload relay or circuit breaker
Keywords: Star delta starter, magnetic contactors, thermal overload.

1. Introduction
Automatic Star/Delta starters are probably the most common reduced voltage starters. They
are used in an attempt to reduce the start current applied to the motor during start as a means
of reducing the disturbances and interference on the electrical supply. Most induction motors
are started directly on line, but when very large motors are started that way, they cause a
disturbance of voltage on the supply lines due to large starting current surges [1]. To limit the
starting current surge, large induction motors are started at reduced voltage and then have full
supply voltage reconnected when they run up to near rotated speed. Two methods used for
reduction of starting voltage are: Automatic Star delta starting and Auto transformer starting.
Nowadays, In industries, the most common type of electric motor used is Induction Motor. If
the motor starts with the direct online method means, it started with the application of
maximum voltage, and starting current will be 7 to 10 times of rated current. So large
induction motors do not start directly, if start means it will damage the winding and other
parts. Motor needs something else to overcome this problem. Automatic Star Delta starter
comes with the need of starting the large indication motors. Automatic Star-Delta starter is a
fine method of starting the induction motor which reduces the starting torque and starting
current to a safe value.
2. Theoretical Back Ground

The induction motor has two main parts. The input power is given to stator. Three phase
induction motor when connected to the power supply the stator produce RMF. The RMF is
the one which makes the rotor turn. As per law, rotor start rotating in direction and reverse
flow the electric current. So, the rotor is like current carrying bars immersed in a magnetic
field. This will induce an electromagnetic force according to Lorentz force law and the rotor
will rotate in the same direction as the RMF. This is how the induction motor works.
Electricity is induced on the rotor bars due to electromagnetic induction rather than direct
connection. Initially the induction motor rotor speed is zero and gradually increase the speed.
This means the rotating magnetic field will cut the rotor bar at very high rate [7]. As the rotor
gain speed, the rate of flux cut will decrease. So, a high current will be induced on the bars at
the start. As the rotor speed increases the current will lower the normal value. At the start
stator current also must be high since the rotor and stator current are coupled due to
transformer action. Due to this the stator coils will draw a huge amount of current when the
motor starts [8][9].

Figure 1.0: Starting current of motor

a. Star or Wye-connected system
When three coils or windings, placed 1200 apart, are connected together at a common point as
shown in below figure, they form star or Y-connected circuit. The common point is called the
Neutral or Star point. When only three main lines are drawn, it is said to be a 3-phase, 3-wire
system. Often a neutral line is also drawn from the neutral point. In this case the system is
called a 3-phase, 4 wire system. The current flowing through each coil is called phase current
and that flowing through main line is called line current. It can be seen in figure that each
phase or coil is connected series with its respective main line. Therefore, in a star connected
system line current is equal to phase current i.e. the same current flows through a phase and
main line connected series with it. In a 3-phase, 4- wire system two different values of
voltage are available. Each coil is connected across a main line and the neutral line as shown
in figure. Therefore, voltage across a coil or phase is equal to voltage between a main line
and the neutral [5]. This voltage is called phase voltage. The voltage between any two main
lines is called line voltage.

Fig 1.1 Star or Y-connected system

 Line voltage, VL = √3VP
The power in a 3-phase, star connected system:
Power per phase = VP IP cosϴ
Hence the total power for all the three phase is given by,
P = 3VPIPcosϴ
= √3VLILcosϴ
Total apparent power of the three phase = 3VPIP
= √3VLIL (VA)
Total reactive power of the three phase = 3VPIPsinϴ
= √3VLILsinϴ (VA) or (VAR)
b. Delta or Mesh Connected system
In delta connection no neutral point is available. With this connection only three-phase, three
wire system is possible.

Figure 1.2: Delta connected of system

In delta or Mesh connection each coil or phase is connected across two main lines. Therefore
in delta connection, line voltage is equal to phase voltage. Two different values of supply
voltage cannot be obtained with this connection [5]. In a delta connected system line current
is equal to √3 times phase current.
Line current, IL = √3IP
The power in a 3-phase, star connected system:
Power per phase = VP IP cosϴ
Hence the total power for all the three phase is given by,
P = 3VPIPcosϴ
= √3VLILcosϴ
Total apparent power of the three phase = 3VPIP
= √3VLIL (VA)
 Total reactive power of the three phase = 3VPIPsinϴ
= √3VLILsinϴ (VA) or (VAR)
3. Materials and Methods
Star delta starter is a starting method that reduces the starting current and starting torque. Star
delta starting is when the motor is connected in STAR during starting sequence and allowed
to accelerate to the normal running speed after which the motor is connected in DELTA. The
most significant advantage of using star delta is the huge reduction in starting current (by
approximately 67%) resulting in cost saving for cables and switchgears. A typical Star delta
starter comprises the following power components: -
i. A backup protective device, either a fuse or circuit breaker
ii. Three contactors switch namely the main, Star and delta contactors
iii. One thermal relay for motor protection
iv. An on-delay timing relay meant to switch on the delta contactor after pre-set time.
v. Manual switches
vi. panel indicators
a. Contactor
A contactor is a heavy-duty relay with a high current rating used to power up the induction
motor. The current rating of contactors varies in the range from 10A to several hundred
amperes. A contactor is controlled by a circuit which has a much lower power level than the
switched circuit.

Figure 1.3: Contactor switch

b. Overload Relay
Thermal overload relays are protecting devices which protect a motor against overload
current and phase failure. It consists of set of indirectly heated bimetallic strips that deforms
whenever the current exceeds limit. It also protects a motor against excessive heating, over-
current, winding and winding insulation.

Figure 1.4: Overload relay

c. Timer Relay
Timer is a control device which control the circuit. It is possible to construct a relay with a
built-in time delay device that causes the relay contacts to switch ON or switch OFF after a
time delay. The main function of the timer in the star-delta starter is to switch the contactor
from star to delta state when motor attains speed nearly about more than 80% of full load
speed. These types of relays are called time delay relays or Timer.

Figure 1.5: Timer & Its Connection

4. Design and Implementation
a. Design Calculation and Wiring diagram
The design of the motor starter and control panel begin with circuit diagrams which comprise
of the power circuit diagram and Control circuit diagram. The schematic diagrams of these
two are shown in fig 1.6 and 1.7 respectively. The purpose of the design calculation is to
determine the rating or the specifications of the various circuit components Involve in the
project in compliance with acceptable engineering standards.
The engineering standard for the design of motor controls can be obtained from National
Electrical Code NEC, American standard, International Electrotechnical Commission IEC or
European Standard. The information available on the motor nameplate forms the basis for the
design of the starter circuit.
The following procedures was strictly followed for the design calculation: -
i. Determining the motor full load current
for an electric motor P = 5.5kw, V = 415v, Cosϕ = 0.86, η=0.9
Po = 1.73 V I Cosϕ η ……………………………………………………..……..(i)
Po = output power in watts
V = supply voltage volts
I = supply current at full load in amperes
Cosϕ = power factor
η= efficiency
Full load supply current (FLA) = 10A
Full load motor winding current (FLW) = 10/1.73= 6A
ii. Determining the size of branch circuit conductor required
NEC 430-22 stipulates that,
conductor ampere = FLA ×125%
= 12.5A for motor supply current
= 7.5A for motor winding current
2.5mm2 supply cable and 1.5mm2 motor cable were therefore selected 12A to 220v as
operation coil voltage. The contactors were wired with 1.5mm2 cable. Taking into
consideration that the size of the contactors should carry the motor winding current
iii. Determining the size of branch circuit overcurrent device
for backup protection
Back up protection refers to protection against short circuits and ground faults. The most
appropriate device is a time delay fuse or inverse time circuit breaker. These devices have
both thermal and instantaneous trip features that allow the motor starting current flow for a
short time without blowing the fuse. NEC 430-152 standard requires that the size of:
a. The inverse time breaker should not exceed 250% of
motor full load supply
 current
b. The time delay fuse should not exceed 175% of motor
full load supply current
This formed the choice of Circuit Breaker rating between 10A – 25A. Therefore, a 25A
circuit breaker was selected for backup protection.
iv. Determining the size of motor overload protection device,
the choice of overload relay is based on the value of full load motor winding current which
will flow through the contactors i.e. 6A. this value must fall between the chosen ranges.
Thermal overload relay of rating 6A – 10A was selected. This selection complies with NEC
section 430-32 which specifies the maximum value of the overload relay rating as FLW x
115% for ambient temperature of 400C and service factor of 1.0.
v. Determining the rating of timing relay, according to NEC standard short circuit or
overcurrent protection devices should be oversized to handle the high inrush current upon
start up so as to prevent frequent nuisance tripping. This is the determining factor in the
selection of timing relay. The recommended size of inrush current is about 6 x full load = 6
x 10 = 60A. The motor run up time is therefore 10 seconds. And a timing relay of range 0 –
30s is acceptable.

Figure 1.6: Power Circuit diagram

Figure 1.7 Control circuits connections diagram

a. Components assembly and cable connection

Assembly of the various control component on the plastic sheet to form a unit was done. The
components were arranged as shown on the following figures

Figure 1.8 a. Indicating lamps and Figure 1.8b. Three phase electromagnetic
Pushbuttons contactor with bi-metal overload relay
Figure 1.8c. Overload Relay Figure 1.8d. Three phase mechanically
interlocked contactors

Figure 1.8e. Main and Sub feeder isolating circuit Figure 1.8f. Power and control circuits fuses
breakers
Figure 1.8g On delay timer Figure 1.8h. selector switch
5. Testing and evaluation

The following test were carried out to ascertain the functionality of the star delta starter that
has been constructed. A preliminary test was first carried out on the motor before connecting
the motor cable.
i. continuity test on the motor terminal: The continuity test
was carried out with a digital multimeter set to the ohms range and connected to the
phase terminal of the motor to determine the continuity of each phase winding.
ii. Insulation test between motor phase winding:
The test was carried out with a 0–1kv megger insulation resistance tester set to the
MΩ range and connected between one phase and another to determine the insulation
resistance between the motor windings.
iii Earth leakage test: phase to earth insulation test
The test was carried out with the megger connected between stator frame of the motor
and to each of the motor terminals
Table1.1 Result obtain from the test
TEST RESULTS
1.Continuity Test Phase R - R Phase Y - Y Phase B - B
0Ω 0Ω 0Ω
 2. Insulation Test Phase R - Y Phase Y - B Phase B - R
7MΩ 6.5Ω 6.8Ω

3.Earth Leakage Test Phase R - Earth Phase Y – Earth Phase B - Earth

10MΩ 10MΩ 10MΩ

4. Off-load Test Switching Timing OK

OK
5. On-load Test Phase R Phase Y Phase B
6A 5.7A 6.3A

The presented system is planned and configured for practical use. This system is able to
reduce high starting current. In this method at first motor terminal connect star system and we
know start connection system line current is equal to the phase current and for this reason
starting time motor achieve low starting current. After five second motor running delta mode
operation. Delta connected system line current is root three times of phase current. So motor
get full voltage and then the motor reaches its rated speed. The motor at starting is reduced to
1/3 as compared to starting current with the windings connected in delta. Finally motor run
without damage. This method is used worldwide.

CONCLUSION

This starting method is used for medium voltage and light starting torque motors. This is one
of the best way to reduce the high starting current. If the large induction motor start in direct
online method, the motor can draw 5-6 times of rated current. The large amount of current
can be easily reduced by the magnetic contactor, relays and the timer circuit. The starter is
designed to provide low voltage start to motors. This is achieved by using star to delta
conversion. Different types of starters are available. Star/Delta starters are most common and
best way to reduced voltage in the 50Hz industrial motor world.
The practical module for star delta starter designed and constructed is characterize by good
finishing, optimal cost, use of contactors for the continuous operation of the motor, decent
arrangement of internal cabling, use of good quality conductors, standard electrical codes and
the need for structural safety has been observed in the project. Compared to the reduced
voltage methods it is the simple and cheapest way of starting the motor
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