FCMA Soft Starter means Flux Compensating Magnetic Amplifier In case of motor driven pumps, while starting, the

motor normally takes 6 or 7 times full load current when started Directly on Line (DOL). Such high values of current have following implications. a) Weakening of insulation and affecting motor life adversely. b) Sudden jerks on incoming line, resulting into large voltage dips, which affect the other sensitive equipment operating on the same line. c) High size of transformer / Generator, as a backup supply system. d) Large jerks on the pumps and associated piping etc.

To eliminate these harmful effects, Soft Starters are used which reduce the starting current considerably and allow the motor to accelerate gradually. The Soft starters provide gradual increase in voltage up to rated voltage ensuring even acceleration. Benefits of Soft Starters The provision of Soft Starters ensures following benefits. a) Smooth starting by gradual acceleration of the drive system, thus preventing jerks and extending life of system components. b) Reduction in starting current preventing mechanical, electrical & thermal weakening of electrical equipment such as motors, cables, transformers and switchgears. c) Enhancement of motor starting duty by reducing temperature rise in stator winding and supply transformer, (subject to thermal curves). d) Increase in Circuit breaker as well as contactor life. To summarize, Soft Starters can optimize the starting performance of motors and motor manufacture can concentrate on improving running performance to ensure lower life cycle costing. Types of Soft Starters Various reduced voltage starting options have been available. The prominent among them are Star delta, Auto transformer, Electronics (Thyristors) and Flux Compensated Magnetic Amplifiers (FCMA) for LT motors. For HT motors predominantly FCMA Soft Starters are employed.

Innovative Technomics Pvt. Ltd. (a Company situated at Pune, India) has developed very innovative FCMA Soft
Starters to cover a wide motor KW range from 0.5 KW to 20,000 KW and supply voltage range from 220 V to 13400 volts. These Soft Starters work on Flux Compensated Magnetic Amplifier basis, (FCMA). This is innovative technology

for incremental motor voltage & torque at constant reduced current. This technology has received wide global acceptance & many FCMA Soft Starters are operating satisfactorily in India & Abroad. In fact the largest Soft Starter for 10500 KW / 11KV motor is supplied for process compressor application in India and a 20000KW/11 KV soft starter is under manufacture. An aggregate of approx. 150,000 KW pump motors are provided with FCMA soft starters, in large pumping schemes in India and abroad. Principle of Operation FCMA Soft Starters are step less reduced voltage starters, which provide a constant low starting current with incremental voltage & torque characteristics to accelerate the motor & pump from stand still to full speed smoothly without any jerks. The FCMA is connected in series with the motor either on the line or neutral side, so that the starting current is limited to a low value. The motor starts smoothly with the reduced current & the reduced torque. As the motor speed increases the impedance of FCMA reduces steplessly to keep the current constant and increase the motor torque so that the load is accelerated.

Theory of Flux Compensated Magnetic Amplifier (FCMA) : The FCMA works on the principle of superimposition of sinusoidal fluxes on a common magnetic core where the net flux is the vector sum of the two components. As the net flux is sinusoidal the FCMA does not generate any harmonics. The motor current is kept constant due to the balancing effect of Cemf feedback. If the motor current tends to increase the main winding flux will increase thus increasing the total flux & increasing the FCMA impedance & reducing the current to the original value. The FCMA is thus primarily a constant current controller & naturally provides current limiting action during the acceleration. Note It is important to note that FCMA is entirely different from Conventional magnetic amplifier. The conventional magnetic amplifiers (saturable core reactors) generate high harmonics content due to saturation & DC injection. FCMA is different and in fact, FCMA is zero Harmonics equipment. This aspect is thoroughly tested and certified while testing in India and Europe. FCMA is totally non-saturable and hence does not generate any harmonics. BYPASS DEVICE The bypass device bypasses the FCMA current controller in the run mode operation. Thus for continuous running of the motor no current passes through the FCMA & the motor gets full voltage. The bypass device essentially is a star contactor operated by fast closing & slow release D.C. magnet. The D.C. supply for operating the magnet is generated internally in the Soft Starter control scheme. The bypass device is designed for bypass duty i.e. to provide an alternative path to an already established current path in the FCMA thus preventing in any sparking during closing operation. The magnet is provided with a retentive core so that even in the event of control supply failure the magnet opens only after 0.5 to 1 sec, thus allowing the control scheme to trip the line side breaker. The bypass device thus is never subjected to current interruption duty & always opens on zero current. The contacts are hence not subjected to any wear & tear. An additional coil protection relay is provided for additional safety. Salient Features of FCMA HT/LT Soft Starters

 Work on Flux Compensated Magnetic Amplifier basis.( FCMA).This is innovative technology for incremental
motor voltage and torque at constant reduced current. Fully sinusoidal current and voltage waveforms without any harmonics and distortion.

Starting currents normally adjustable from 2-4.5 times full load current, depending upon load and motor
characteristics. The values of starting current can be adjusted at site and six such adjustments are provided. Built in RUN mode by pass contactor.

Virtually no maintenance & can work in extreme ambient conditions. FCMA is natural air -cooled. No forced cooling required. Unique neutral side connection for high voltage units limits fault rating of soft starters and makes them very
economical as well as very reliable . Can be retrofitted into existing systems without any major modifications. No special protections are required for soft starters. Conventional motor protections are sufficient. The general standards applicable are IS325/ IEC34 / BS4999 / BS5000

Unique advantages of FCMA Soft starters

Smooth and step-less starting with very smooth by pass without any change over kick. Closed transition hence no
momentary disconnection of supply. Amplitude control provides fully sinusoidal wave forms and hence totally harmonics free.

FCMA has no moving parts and hence no wear and tear. No active electronic components and hence not prone to failure due to power supply spikes. High thermal withstand. No maintenance . Very reliable and user friendly. Easy to operate. Suitable for indoor/ outdoor installation depending upon requirements. FCMA assists optimisation of backup supply transformer/ generator. It can also optimize total power system.

Smooth Starting assisted by FCMA Soft Starter A] Genset starting Considerations Engine step loading Alternator KVA overload capacity Alternator KVAR capacity Soft starter advantages Reduces torque hence power and Engine step load Reduces KVA loading Reduces KVAR loading and voltage drop Result User can optimize selection of Genset rating if motor is started with soft starter. This leads to large saving in Genset capacity and cost. Additionally the Genset will run at optimum load and efficiency, leading to fuel saving.

B] Transformer starting Considerations Transformer p.u. impedance

Transformer KVA overload capacity Soft starter advantages Reduces KVA loading Reduces KVAR loading and voltage drop Result Customer can optimize selection of transformer rating if motor is started with soft starter. This leads to saving in transformer capacity and cost. C] Starting of Motors on Limited Power Capacity Starting current limited to 2-3 times instead of 6 times as in DOL

Voltage drop in transformers and Generators is limited to acceptable values Current load on transformers and generators is limited within safe limits Protection relays can be set for close protection Nuisance tripping during starting avoided
Conclusion : The application of FCMA Soft Starter with motor ensures optimisation of starting performance. Hence motor manufactures can ensure optimisation of starting & running performance with the help of FCMA Soft Starters & finally achieve lower life cycle costing.