Understand working principles of motor starters and various protection devices

Motors and Motor Control

Oladokun Sulaiman
 Objective

• At the end of the lecture students will be able

to describe the working principles of motor
starters and various protection devices
 Motors
• A motor is basically a generator running in
reverse.
• A current is passed through the coil, producing
a torque and causing the coil to rotate in the
magnetic field.
• Once turning, the coil of the motor generates a
back emf, just as does the coil of a generator.
• The back emf cancels some of the applied emf,
and limits the current through the coil.

3
 Motors and Back emf
• The phrase back emf is used for
an emf that tends to reduce the
applied current
• When a motor is turned on, there
is no back emf initially
• The current is very large because
it is limited only by the resistance
of the coil

4
 Motor
• DC
• AC
AC Motor
• Induction motor
• Synchronous motor
• Wound rotor motor
Operate based on Speed (S)= 120f/p
• F-Frequency
• P-Number of poles
6
 Control
Control: getting motors to do what you want
them to
What you want to control     =     what you can control
For DC speed
motors:
voltage
windings’
resistance

R
N
ω
V V e back
N S emf

e is a voltage generated by the

rotor windings cutting the
magnetic field
 Needs for Motor Control
1. Induction motor – drawn 5-8x full-load current
(FLC) when starting
2. Due to maximum flux cutting rate (s = 100%)
in rotor- creating large induced rotor currents
3. Supply power factor very low i.e. 0.2 lagging at
starting, 0.5 lagging on no-load & 0.85 lagging
on full-load
4. This starting surge current reduces as motor
accelerates up to rated speed
5. Operating at light loads with low power factor -
inefficient as supply current higher causing
higher I²R (copper) losses
6. To improve - reduce supply voltage for light
loads motor
7. Achieved with electronic voltage controller i.e.
soft-starter and/or energy manager - match
supply voltage to start-up & load conditions
8. This will maintain operating power factor as
high as possible - minimise supply current &
power losses
9. Most induction motors have Direct-on-Line
(DOL) - inexpensive & simple to operate &
maintain provided current surge not cause
heating damage to motor
10. When larger motors started by DOL – can cause
voltage dip due to large starting current
11. May result in malfunction of others - lighting dip
& flickering effects
12. To limit, motors started at reduced voltage- full
supply reconnected when accelerated close to
rated speed - star-delta, auto transformer &
electronic "soft" starter
 Motor
1000

100
Characteristics
Normal Operating Current
10
Seconds
Time in

0.1
Inrush Current

0.01
1 10 100 1000 Motor Inrush Curve
Current in Amperes
 1000 1000

100 100

300 % Overload

Short Circuit
10 10

Seconds
Time in
Seconds
Time in

1 1

0.1 0.1

0.01
0.01
1 10 100 1000
1 10 100 1000
Current in Amperes Current in Amperes
 COMPARISON OF STARTERS
60 DIRECT ON
0 LINE
STARTING

40
Current %

0
AUTO
TRANSFORMER
20 STARTING
0 STAR
DELTA
STARTING
0
10 Slip 0
0 Auto transformer
%
on 60%
 Contactor

Performing switching action to connect/disconnect

power supply to motor. Electromagnetically
operated 3-pole switch initiated from local, remote
stop/start push buttons. If current above rated,
 Direct on line
• Simple arrangement, used for majority induction motor
• Motor directly switched onto 3 phase AC power supply
lines
• Further circuit additions – remote control & reversing
(required extra contactor)
• Short duration but large starting current
• Acceptable provided voltage dip < 10~15% during
starting
• For larger motor - unacceptable voltage dip at bus-bars -
malfunctions of other consumers & possible drop out of
supply contactors
• If prolonged – cause supply line & generator protection to
trip
 Power circuit operation
Manual closing of fused isolator
Q1
Closing of line contactor KM1
KM1 contactor ‘holds-in”
KM1 contactor drops out, motor
stops
Control circuit operation
Control circuit voltage available
(e.g. 110V from control
transformer)
Press start button “I” (local or
remote)
Auxiliary contact on KM1 ‘latches’
contactor
Remote indicator lamp ‘on’
Press stop button ‘O’ (local or
remote) on overload the OCR trips
out the stop button
OCR must be manually reset (after
thermal time delay)
 Star delta
• If motor stator winding is star connected, only 1/3 of
starting current required if motor start with delta
connected
• For small motors – operated by manual c/o switch
• For large motors - phase windings automatically
switched using timing controlled contactors
• At initial starting, motor won’t rotate, thus no
mechanical output produced
• Therefore, current taken by the motor will determine
by supply voltage & impedance of motor phase
windings
Power circuit operation Control circuit operation

Manual closing of fused isolator Q1 Control circuit voltage available

(e.g. 110V from control transformer)

Closing contact of KM1: star Press start button S2 to close KM1

connection
Closing of KM2: motor supply KM1 closes KM2

Opening of KM1: star connection “hold in” of KM1 – KM2 by KM2

opens auxiliary
Closing of KM3: delta connection Opening of KM1 by KM2 auxiliary
Closing of KM3 by KM1 auxiliary

KM2 & KM3 contactors drop out, Stop by S1 button or OCR trip F1
motor stops
Note: KM2 has a pair of auxiliary contacts with a time delay action (typically 40ms)
between the operating of the N/C and the closing of the N/O contacts.
Comparison if star & delta connection

VL
I L (Y ) 3.Z 1
Ratio = =
I L(∆) 3.VL 3
of Z
 Current surge from star to delta
• Motors generate back emf against power supply when
running
• When supply removed, magnetic field does not
collapse immediately
• Motor will slow down but still generate emf
• When supply reconnected, supply voltage & motor
emf are not in phase
• Thus each time the starter is operated, different
current surge will produced
• To overcome – auto transformer is used where the
supply is eventually never disconnected during
starting period
 Auto transformer
• Starting large motor with prolong run-up period demand very
high current surge from supply generator even for few
seconds
• Will causes severe voltage dip - affects other loads
• Reduced voltage starting will limit starting surge current
• One method – step it down using transformer
• When motor accelerated up to almost rated speed, then
“reduced” voltage will resume to normal
• Special transformer – uses one winding for input & output
• Thus, cheaper, smaller & lighter than equivalent double-
wound transformer
• Meant for operation of short starting period only
• Only applicable to large motor drives due to initial cost
Power circuit operation
Manual closing of fused isolator Q1
Closing KM1: star connection of
transformer
Closing KM2: motor supply via
transformer
Opening KM1: star connection opens
Closing KM3: direct supply to motor
(Note the mechanical interlock of KM1- Hold in of KM3
KM3)
KM3 contactors drop out, motor stop
Control circuit operation
Control circuit voltage available
(e.g. 110V from control transformer)
Press start button S2 to close KM1
Interlocking of KM3 by KM1
Closing KA1 by KM1
Closing of KM2 by KA1
Hold in of KM2
Opening KM1 by KA1 (after time
delay)
Closing KM3 by KM1
Interlocking KM1 by KM3
Opening of KM2 by KA1
Stop by S1 button or OCR trip F1
 Auto transformer - operation
• Supply voltage connected across complete winding & motor
connected to reduced voltage tapping
• Number of tapping available - giving output voltage ranging from
50% ~ 80% of main supply
• If 60% tap supplied at 440 V, output will be 60% x 440 = 264 V
• Multiple tapping - to match motor current demand to supply
capability
• Autotransformer can be use in both open & closed transition
switching sequence between start & run conditions
• Star delta - reduced voltage initially supplied, disconnected & then
full supply voltage rapidly reconnected to motor – open transition
• Danger with open-transition - very large surge current can flow
after transition from reduced to full voltage
Soft starter (additional)
 Conclusion
• DOL starter - simple & cheap but causes large
starting surge
• Star delta starting reduces surge but more
complex – require 3 contactors & timer
• Auto transformer - can arranged to match
motor surge current & run-up period with
suitable voltage but the most expensive one
 Controlling speed with voltage

• The back emf depends only on the motor speed. e = ke ω
• The motor’s torque depends only on the current, I. τ = kτ I

V e

DC motor model
 Controlling speed with voltage

• The back emf depends only on the motor speed. e = ke ω
• The motor’s torque depends only on the current, I. τ = kτ I
Istall = V/R
current when
• Consider this circuit’s V: V = IR + e
motor is stalled
speed = 0 How is V related to ω ?
torque = max

τ R
V =         + ke ω 
R  kτ 
V e
­ or ­

 R  V
ω = ­         τ +
 kτ ke     ke 
Speed is proportional to voltage.
DC motor model
 speed vs. torque at a fixed voltage
speed ω

 V no torque at max
speed
   ke 

max torque when

stalled

 kτV
torque τ 
   R 
 speed vs. torque at a fixed voltage
speed ω Linear mechanical power  Pm =  F • v 
Rotational version of Pm =  τ • ω 
 V no torque at max
speed
   ke 

 kτV stall torque

torque τ 
   R 
 speed vs. torque at a fixed voltage
speed ω Linear mechanical power  Pm =  F • v 
Rotational version of Pm =  τ • ω 
 V
   ke 
max speed
power
output

speed vs.
torque

 kτV stall torque

torque τ 
   R 
 Motor specs

Electrical Specifications (@22°C)

For motor type 1624   003S 006S 012S 024
­­­­­­­­­­­­­­­­­­­­­­­­­­ ­­­­­­­­ ­­­­­­­­ ­­­­­­­­ ­­­­­­­­­         ­­­­­­­
nominal supply voltage (Volts) 3 6 12 24
armature resistance (Ohms) 1.6 8.6 24 75
maximum power output (Watts) 1.41 1.05 1.50 1.92
maximum efficiency
no-load speed
(%)
(rpm)
76
12,000
72
10,600
74
13,000
74
14,400  kτ
no-load current (mA) 30 16 10 6

   ke  friction torque

stall torque
(oz-in)
(oz-in)
.010
.613
.011
.510
.013
.600
.013
.694
velocity constant (rpm/v) 4065 1808 1105 611
back EMF constant (mV/rpm) .246 .553 .905 1.635
torque constant (oz-in/A) .333 .748 1.223 2.212
armature inductance (mH) .085 .200 .750 3.00
 Back to control
Basic input / output relationship: We can control the 
voltage applied V.

τ R We want a particular 
V =         + ke ω  motor speed ω .
 kτ 

How to change the voltage?

V is usually controlled via PWM -- “pulse width

modulation”
 PWM
• PWM -- “pulse width modulation

• Duty cycle:
– The ratio of the “On time” and the “Off time” in one cycle
– Determines the fractional amount of full power delivered to
the motor
 Open­loop vs. Close­loop Control
Open­loop Control: 
V(t)
desired speed ω Controller  Motor ω
solving for V(t)
actual speed

If desired speed ωd  ≠ actual speedSo

ωa, what?

Closed­loop Control:  using feedback
ωd  − ωa
ωa
desired ωd V
compute V from 
­ the current error
Motor

PID controller

actual speed
ωa
 Speed control:

• Stator voltage control

• Supply frequency control
• Rotor resistance control
• Pole changing
 VSD
• Conventional control of supply frequency and terminal
change of phase to minimize losses – counter current
/pluging+ regenerative +dynamic
• Development in speed and torque control
• From ward leornard system -> thyristor controlled DC drive
->PWM AC variable voltage regulation ->variable frequency
converter-> AC VSD or inverter
• Cost effective method of speed control+ application to high
power+relibaility+maintainability+save energy+ improve
efficiency+ match speed and torque of drive with process drive
Backdrop- complexity
 Component-
• Motor
• drive control unit-power source to motor, increase and
decrease motor set point at operator panel+ feed back loop
give the driv the actual speed+Power modulation – control the
speed , torque and power along with direction of motor and
machine- i.e converter, inverter, cycloconverter.
• +sensing unit
• +operator unit
Different Categories of Overload
 Protection
Motor enclosure
• Totally enclosed , non ventilation
• Splash –proof type
• Totally enclosed fan cooled
• Drip proof type
Name plate- rating, supply , connection ,frame
type and size,permisible temperature,rpm,
enclosure type,# of pole.
 Motor Protection
1. Short-circuit protection of stator windings
2. Stator-overheating protection
3. Rotor-overheating protection
4. Under voltage protection
 Protection
Measurement Testing:
• Temperature No load test
Full load test k
• Voltage and current-
• Insulation resistance
winding resistance
• Vibration
• Speed
•
Failures:
• Insulation failure
• Rotor bar failure
• Mechanical problem
Maintenance
Periodic inspection-
Accurate shaft alignment or belt tension
Check motor heating@ heating- check and clean air filter
Keep motor clean and free from dirt
Keep motor dry - Check for dampness around and inside motor
Check bearing regularly- lubrication at right quantity
Vibration analysis- of motor and coupling
 Circuit Breaker
• Safely & interrupt prospective short circuit fault
current expected in circuit
• Will trips but can be reset & reused
• Link mechanism provided, closes main contacts
under spring pressure & wipes the surface of
fixed contact points - ensuring good electrical
contact
• Main contact open rapidly with snap action
• Resulting arc transferred to special arcing
contacts above the main contact
• Arc chutes with arc ‘splitter’ quickly stretch &
cool the arc till it ‘snaps’
• Circuit breaker is ‘open’ when the arc quenched
The Magnetic
Trip Block
 Fuse
• Protect circuit from damage – faults & over
current
• Designed to blow rapidly before circuit damage
takes place
• Many types and sizes, marked with size of steady
current can be carried without blowing - fuse
rating Transparent casing
Tinned wire copper

Brass cap
 Fuse Rating
• Important – correct rating for normal current
flowing in circuit it protects
• Lower rating - every time switch on, fuse will
blow
• Higher rating – promoting positive dangerous
circuit with over current flowing without blowing
fuse - overheat & can cause fire
• If fuses blow, must replaced by same type &
same rating
• Position - between supply and the circuit – fuses
removal means total isolation for the circuit
• Two main types:
– Cartridge fuse
– High rupturing capacity (HRC) fuse
Checking Fuses: Visual inspection
Relays are amazingly simple devices.
There are four parts in every relay:
• Electromagnet
• Armature that can be attracted by the
electromagnet
• Spring
• Set of electrical contacts
Case study 1: How a relay works?
 Case study 2: Under voltage trip
3-ph 440V bus bars

Circuit
UV relay
breaker
coil
Fuse

Generator
 Case study 3: Single phasing

Normal Condition What happened?

1.4 A 0A

1.4 A
2.4 A
M (173%)
M
1.4 A (173%)
2.4 A
208V 1/3 HP Motor 40 C
F.L.A. = 1.4 Amperes
 Bi-metallic Single-phasing
Protection (differential action)
 Single phasing
• Occurs when one of three back-up fuses blows or if one of
contactor contacts is open-circuited
• Effect – current increase in two remaining lines
• Cause noisy motor – uneven torque produced in rotor
• Will detect by OCR – unequal heating of bi-metal strips
causes differential movement, initiate OCR to trip motor
contactor
• For star connected motor – phase & line currents are equal,
thus OCR has no problem in sensing correct winding
current
• For delta connected – uneasy task, therefore, normally line
current will divides phasorally between 2 phases of motor
windings
IL
I PH = = 0.577 I L
3
Single phasing
 Healthy
Single phasing fault condition
condition
(unbalanced)
(balanced)
% of rated FLC
% of rated
FLC IL2 and IL3 IA and IB IC

60 102 62 131
70 130 79 161
100 243 129 185
 Facts of single phasing
• When one line open circuited, balanced condition will no
longer exists
• Note that current C is higher than others
• At 60% of full load, due to single-phasing, line currents are
102% of full-load value but current C is 131%
• 102% may not activate OCR, thus motor remains connected
• However, local overheating in winding C will quickly get
damage
• Differential type relay used to protect motors against this
condition i.e. trips out with unbalanced currents
• For most modern thermal OCR - protection against single-
phasing - normal feature
 Effect of single phasing

• If single-phasing occurs on light load, motor will

keep running unless protection trips contactor
• If motor stopped, it won’t restart
• When contactor closed, motor will take large starting
current but develop no rotating torque
• OCR - set to allow starting current at prolong period
– sufficient for start up period
• With no ventilation on stationary motor - time delay
will result rapid & severe overheating
• Worse case - if operator makes several restart, motor
will burn out
 Effect of single phasing (cont/..)
• If motor fails to start – investigate first
• UV protection - disconnected consumers from supply if
total voltage loss / black-out, prevent restarting together
resulting huge current surge, tripping generator again
• For LV motors – UV provided by spring loaded motor
contactor
• For large HV motor - UV covered by relay separate from
OCR function or part of special motor relay
• Motor won’t restart until contactor coil energised –
require operator to reset manually
• For essential services – restart automatically after certain
delay is utmost important
 Willas-Array Solution for Motor Control
Block Diagram 1

AC BLDC
Input Motor
PWM Signal Hall Sensor
(Inside Motor)

Control
Power Unit Gate Driver
Management
With Gate Driver
Motor Gate Driver
Power Stage
Control
= 6 x IGBT
Cell 3 x Driver IC or MOSFET

IPM Module
Feedback Signal
Others
(Speed / Positon)

61
 Inspection & maintenance
• Moving contacts in control gear - ‘wipe’ phenomenon i.e.
if fixed part need to removed, moving part would follow
on
• Rolling / sliding action of contactor - to remove any
oxide, ensure good metal-to-metal contact
• Frequently operate contact – subject to worn, bad contact,
‘wipe’ lost, reduction in contact pressure & overheating –
regular inspection & cleaning
• Rough contact surface could lower contact resistance -
file used sparingly & only on badly burned & pitted
contacts
• Contact restorer - helps reduce mechanical wear, but
excess oil / grease encourages burning & pitting
• Silver-faced & carbon contacts shouldn’t be lubricated
 Inspection & maintenance (cont/…)
• Closed copper contacts with long periods tend to build
oxide film - cause overheating
• Operated contact several times – to clean surfaces
• Magnet faces - kept clean & free from grease/oil, rust
removed using fine emery
• Moving parts – free, no undue wear at pivots, magnets
bedding properly & no filing on magnetic faces
• Enclosure – dirt/rust accumulations, corroded parts,
starter fixing bolts & earth bonding connection
• Contactors & relays – signs of overheating & loose
connections, dust/grease from insulating components
 Inspection & maintenance (cont/…)

• Contacts – excessive pitting & roughness

• NEVER file silver alloy contacts or remove silver oxide -
good conductor
• If need to replace, always replace both fixed & moving
contacts in pairs
• Connections – power & control connections for tightness,
overheating, fraying & brittleness flexible leads
• OCR - proper size (relate to motor FLC),
dirt/grease/corrosion & freedom of movement
• Control operation – sequence during start-up, control &
shut-down, excessive contact sparking, functioning of
emergency stop & auto restart