Automatic Star/Delta Starter Using Relays and Electronic Timer for 3 Phase Induction Motor

Project Guide:Mr. Swapnil N. Jani

Submitted By:Rohan Rustagi (10BEE0029) Rushil Wadhwana(10BEE030)

Introduction
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. 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 are used for reduction of starting voltage are : 1. Star delta starting 2. Auto transformer stating.

Working Principle of Star/Delta Starter

Voltage reduction during star-delta starting is achieved by physically reconfiguring the motor windings.

The motor is connected in STAR during the starting and when the motor is accelerated close to the 75% of the rated speed, the motor is connected in DELTA.

Starting Voltage Reduction =Vline /3 Hence starting current is reduced

Controlling the interchanging star connection and delta connection of an AC induction motor is achieved by means of a star delta or wye delta control circuit. The control circuit consists of push button switches, auxiliary contacts and a timer.

Fig. 1: DOL Starter

Fig 2: Star-Delta Starter

Circuit Diagram
1. Power Circuit

2. Control Circuit (3 wire control)

The Star and Delta are electrically interlocked and preferably mechanically interlocked as well. In effect, there are four states: 1. OFF State. All Contactors are open 2. Star State. The Main and the Star contactors are closed and the delta contactor is open. The motor is connected in star and will produce one third of DOL torque at one third of DOL current. 3. Open State. The Main contactor is closed and the Delta and Star contactors are open. There is voltage on one end of the motor windings, but the other end is open so no current can flow. The motor has a spinning rotor and behaves like a generator. 4. Delta State. The Main and the Delta contactors are closed. The Star contactor is open. The motor is connected to full line voltage and full power and torque are available.

Features of star-delta starting

For low- to high-power three-phase motors. Reduced starting current Six connection cables Reduced starting torque Current peak on changeover from star to delta Mechanical load on changeover from star to delta

Effect of Transients
During transition period of switchover the motor must be free running with little deceleration. While this is happening Coasting it may generate a voltage of its own, and on connection to the supply this voltage can randomly add to or subtract from the applied line voltage. This is known as transient current. Only lasting a few milliseconds it causes voltage surges and spikes. Known as a changeover transient.

Contactors
A contactor is an electrically controlled switch used for switching a power circuit, similar to a relay except with higher current ratings.[1] A contactor is controlled by a circuit which has a much lower power level than the switched circuit. Contactors come in many forms with varying capacities and features. Unlike a circuit breaker, a contactor is not intended to interrupt a short circuit current.

A contactor has three components. The contacts are the current carrying part of the contactor. This includes power contacts, auxiliary contacts, and contact springs.
Apart from optional auxiliary low current contacts, contactors are almost exclusively fitted with normally open ("form A") contacts. Unlike relays, contactors are designed with features to control and suppress the arc produced when interrupting heavy motor currents.

Utilization categories for contactors according to IEC 60947-4-1

The current rating of the contactor depends on utilization category. For example IEC categories are described as: AC-1 - Non-inductive or slightly inductive loads, resistance furnaces AC-2 - Starting of slip-ring motors: starting, switching-off

AC-3 - Starting of squirrel-cage motors and switching-off only after the motor is up to speed. (Make Locked Rotor Amps (LRA), Break Full Load Amps (FLA))
AC-4 - Starting of squirrel-cage motors with inching and plugging duty. Rapid Start/Stop. (Make and Break LRA)

NEMA Size
NEMA (National Electrical Manufacturers Association) contactors and motor starters are rated by sizes. These sizes are grouped by rated current and horsepower.

Size of each part of Star-Delta starter

(1) Size of Over Load Relay: For a star-delta starter there is a possibility to place the overload protection in two positions, in the line or in the windings. Overload Relay in Line: In the line is the same as just putting the overload before the motor as with a DOL starter. The rating of Overload (In Line) = FLC of Motor. Disadvantage: If the overload is set to FLC, then it is not protecting the motor while it is in delta (setting is x1.732 too high). Overload Relay in Winding: In the windings means that the overload is placed after the point where the wiring to the contactors are split into main and delta. The overload then always measures the current inside the windings. The setting of Overload Relay (In Winding) =0.58 X FLC (line current). Disadvantage: We must use separate short circuit and overload protections.

2) Size of Main and Delta Contractor: There are two contactors that are close during run, often referred to as the main contractor and the delta contactor. These are AC3 rated at 58% of the current rating of the motor. Size of Main Contactor= IFL x 0.58 (3) Size of Star Contractor: The third contactor is the star contactor and that only carries star current while the motor is connected in star. The current in star is 1/ 3= (58%) of the current in delta, so this contactor can be AC3 rated at one third (33%) of the motor rating. Size of Star Contactor= IFL x 0.33