Application Notes

HOW TO SUCCESSFULLY APPLY MEDIUM VOLTAGE SOFT STARTERS

HOW TO SUCCESSFULLY APPLY MEDIUM VOLTAGE STARTERS

Application Challenge

The selection of a suitable selection of a suitable starting method for a motor/load combination is becoming increasingly important as additional loads are added to existing utility and distribution systems. In the past, ample capacities were available in the utility networks to support the needs of industry. As well, the distribution systems of most North American industries were established during the industrial and technological boom years preceding the Second World War. In the 1990s, the viability for the construction of new electrical generation plants became prohibitive. With lower North American utility generating capacity and increased risks involved in the de-regulation of this utility, stability and voltage drop concerns have become very real issues that face all electrical power consumers. Problem Full voltage starting of motors can produce objectionable voltage flicker, mechanical stress to gear boxes or belt drive systems and create pressure surges or water hammer in pumping applications. Starting a motor at reduced voltage can help reduce or overcome these problems. If the load cannot be accelerated to full speed using full voltage and current, it cannot be accelerated to full speed using reduced voltage and current.

Application Solution

There are several factors to be considered when selecting the starting equipment for any electric motor driven load. These include, but are not limited to: 1. The source of power and the effects the motor starting currents will have on the source and the stability of the system voltage. 2. The starting and breakdown torque characteristics of the motor (motor speed torque characteristics) 3. The motor starting characteristics (torque) that correspond to the motor best suited to the load characteristics at full load and speed 4. The starting characteristics of: motor torque load torque, accelerating load torque (load inertia) the motor starting, accelerating and running torque on the driven load 5. The available short circuit capacity of the distribution system 6. The operating speed range of the connected load 7. Process considerations: shock, vibration, mechanical hammer, the control and maintenance of different starting methods. The initial inrush currents, locked rotor currents and the resulting torque values produced, are the factors that determine whether the motor can be applied directly across the line, or whether the current has to be reduced to get the required performance to match the load requirements and/or utility line voltage flicker or voltage dip specifications.

HOW TO SUCCESSFULLY APPLY MEDIUM VOLTAGE STARTERS

Full voltage starting can be used whenever the driven load can withstand the shock of instantaneously applying full voltage to the motor and where line disturbances can be tolerated. Full voltage starting uses a main contactor to apply the motor stator windings directly across the main system voltage. This type of starting method provides the lowest cost, a basic and simple design of controller, resulting in low maintenance and the highest starting torque. Reduced voltage starting may be required if full voltage starting creates objectionable line disturbances on the distribution system or where reduction of mechanical stress to gear boxes or belt drive systems is required. It must be noted that when the voltage is reduced from nominal, a decrease in inrush current will occur at a rate of 12% for every 10% decrease in voltage. The starting torque will also decrease at a rate of 20% for every 10% decrease in voltage. This phenomenon also occurs in the opposite manner when the voltage is increased. Figure 1 depicts the behavior of the current required by an 1800-RPM induction motor at various speeds. Two facts stand out: First, the starting current is quite high compared to the running current; and second, the starting current remains fairly constant at this high value as the speed of the machine increases and then drops sharply during the last portion of acceleration to full operating speed.

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Figure 1 Motor Current Speed Curve

This means, of course, that the heating effect, to the rotor and the windings, is quite high during acceleration since it is a function of IT. It also means that a motor may be considered to be in the locked rotor condition during nearly all of the accelerating period.

HOW TO SUCCESSFULLY APPLY MEDIUM VOLTAGE STARTERS

Figure 2 shows a set of torque-speed curves for a typical variable torque load (such as a fan, blower or unloaded centrifugal compressor) and induction motor that could be coupled to a typical induction motor. At this point, it should be mentioned that both the current-speed and torque-speed curves shown are examples of only one particular class of induction machine. As noted previously, the shape of these curves for any individual motor depends mostly on the configuration, material and placement of the rotor bars. Every load and motor combination will exhibit unique torque speed and current speed curves.

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Figure 2 Torque / Speed Curves

The examples shown in Figure 2 is the closest to the typical characteristics of a Class B induction motor. As the horsepower gets higher, the percentage starting torque will be lower and the sag in the torque-speed curve will become more pronounced. The torque of an induction motor is a function of the square of its induced rotor current, and is therefore approximately the square of its line current. If the starting voltage is reduced to 50%, the motor current will drop to 50% of normal full voltage starting current, but the torque will drop to 25% which comes from (0.5)^2 = 0.25 or 25%. Were it not for this fact, reduced current starting methods would not create the problems that they do. The inverse is also true. If you increase the voltage the torque will increase in the same proportion. See Figure 3.

HOW TO SUCCESSFULLY APPLY MEDIUM VOLTAGE STARTERS

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Figure 3 % Voltage / Speed Curves

Reduced Voltage Starting

There are three main reasons to apply reduced voltage to medium voltage motors: 1. To reduce the mechanical effect of across the starting and stopping (Soft Start/Stop) 2. To limit the inrush current inherent with full voltage starting (Voltage Ramp/Current Limit) 3. To reduce the effects of pressure surges and water hammer in pumping systems. (Pump Control) Mechanical Shock This reason for applying reduced voltage has various different names; it can be called mechanical shock, mechanical stress, or various other names. The effect is the same. When a medium voltage motor is started at full voltage the torque being applied from the motor to the driven load rises to a very high value almost immediately. This can cause damage to the bearings in the motor or the load, the rotor of the motor or to the mechanical coupling method which connects the motor to the load. The load itself can sustain damage depending on what the application may be. In the case of conveyor application if the load is started to quickly the belts of the conveyor can be stretched or broken. If the motor is connected to the load via chains or belts these coupling means can be damaged as well by sudden starting techniques.

HOW TO SUCCESSFULLY APPLY MEDIUM VOLTAGE STARTERS

Utility Restrictions As utility power systems continue to be run at maximum capacity the effect of starting medium voltage motors across the line can put stress on the factorys power distribution system. The lights go dim, process control systems can fail or trip out or you may be restricted as to when and how often you are allowed to start the motor. Load Related Reasons Many of our MV SMC Flex applications have been purchased based on system performance improvements. By soft starting the load the customer may see improvements in the way the equipment performs. For example, when a soft starter is applied to an agitator by slowing ramping up the speed of the motor the material being agitated tends to splash less and causes fewer problems than when started across the line. In the case of mill applications the material will start to move slower than when started across the line and cause less wear on the driven load. The ways in which a soft start can improve system performance are only limited to the number of applications that the end user can think of. New uses are being thought of and applied all the time. Torque Requirements It is important to reiterate that when the voltage is reduced when starting a motor, so are the current and torque values. It should be apparent that a motor that will not start a load at full voltage, it will not start that same load under reduced voltage conditions. This conflict between torque and current requirements of induction motors is one typical dilemma facing the user of reduced voltage starting equipment. It may be only one of several problems but is the most common and most important. Reduced voltage starting can be accomplished in several different ways. Reactor Starting This method also reduces the voltage, current and torque to the motor according to the reactor tap setting. It is possible to reduce the motor terminal voltage as required by placing a primary reactor in series with the motor windings, for a period during starting. The use of a reactor during starting results in an exceptionally low starting power factor. Reactors must be carefully designed and applied since any saturation in the reactor will produce in-rush currents close to those seen during full voltage starting. Reactor starting has one major advantage; the voltage to the motor is a function of the current taken from the line. It can therefore be assumed that during acceleration the motor voltage will rise as the line current drops. This relationship results in greater accelerating energy at higher speeds and less severe disturbances during the transition to full voltage.

HOW TO SUCCESSFULLY APPLY MEDIUM VOLTAGE STARTERS

Autotransformer Starting Autotransformer starting automatically switching between taps of an autotransformer reduces the voltage, current and torque to the motor according to the tap setting used on the autotransformer. There are two very distinctive characteristics of an autotransformer starter. 1. The motor terminal voltage is not a function of load current and remains constant during the acceleration time. There is some regulation within the autotransformer however this is negligible. As well, from the standpoint of overall power factors, the magnetizing currents are also negligible. 2. Due to the turn ratio advantages, the ratio of primary line current to torque is the same for autotransformer starting as for full voltage starting. The primary line current is less than the secondary motor currents. Since the turn ratio also represents the voltage ratio, the starting current is reduced by the square of the turn ratio. It should be noted however that the motor current and line current are not equal as they are with a primary reactor. A three-coil autotransformer is connected in a wye configuration and connected to the motor in such a way as to supply reduced voltage to the motor when the line voltage is applied to the Autotransformer. Several sets of taps are usually available to the user to provide different values of reduced voltage (NEMA standards are 80%, 65% and 50% of the full line voltage). Solid State Reduced Voltage Starting The use of solid state Reduced Voltage Starting can provide a smooth stepless method of accelerating and smoothly decelerating a squirrel cage induction motor. This type of starting method, when properly applied can provide an efficient and reliable means of smoothly starting and stopping a motor and load. The use of solid-state reduced voltage starting will perform, in most cases, more efficiently than field coupling, eddy current drives and clutches. The stepless ramped acceleration and deceleration capabilities of these types of starter reduces the inrush currents to the motor, eliminating transitional shocks to the load and reducing voltage flicker on the distribution system.

HOW TO SUCCESSFULLY APPLY MEDIUM VOLTAGE STARTERS

Selection of Appropriate Starting System

The selection of an appropriate starting system requires the reviewer to compare or weigh the importance of several factors. Cost and Economics: When determining the starting method, the economics of the decision can also provide important tips to the selection of an appropriate controlling means. Maintainability: The capabilities of the mechanical and electrical support facilities and personnel can have an important impact on the starting method determination. Remote Control Requirements: As businesses become increasingly more competitive, the reductions in the area of personnel related to the control and operation of industrial processes are becoming dramatic. This required reduction of personnel has subsequently hastened the development of the remote control capabilities of modern motor control equipment. In many cases, production flow and efficiency rate adjustments can be critical to the quality of the end product. For example in the case of remote pumping stations, the ability to control the speed of a booster pump, based on the product in the line at the time, can allow a remote location to monitor and adjust flow rates to maximize the capacity of the pipeline. Process Control Requirements: In todays competitive environment, industry is endeavoring to continually improve processes to produce high quality products, at accelerated periods, at the least possible cost. If the process requires variation of speeds, a controller that will vary the motor speed would be appropriate. If depressed distribution voltage, during motor start cycles, is an issue, a solid state or other reduced voltage starting method may suffice. Physical size restraints: The limitations of available physical floor space could be a major concern when retrofitting new equipment into an existing control area. The physical construction of equipment housing the newer technology may not be suitable incorporated within existing facilities. Careful consideration may be required for the removal of heat generated by semi-conducting devices, printed circuit cards, transformers and other electronic control devices. Cooling systems may be needed to aid in the maintenance of a suitable environment for these types of equipment. Ease of use: One consideration that is sometimes overlooked is the capabilities of the personnel required to service and maintain the equipment. Simpler more traditional starting means may be suitable where basic personnel training levels are maintained. The simpler relay control logic systems may be adequate for the system configuration required for the specific process.

Medium Voltage Products, 135 Dundas Street, Cambridge, ON, N1R 5X1 Canada, Tel: (1) 519.740.4100, Fax: (1) 519.623.8930, www.ab.com/mvb
Publication 1560E-WP023A-EN-E November 2006
Copyright 2006 Rockwell Automation, Inc. All rights reserved. Printed in Canada.