ELECTRICAL DRIVES

AND INDUSTRIAL AUTOMATION

Introduction
DRIVES: APPLICATION
REQUIREMENTS
1- STARTING/ BRAKING
 Physiological Aspects
Application: Lift requiring certain
degree of comfort.

Solution: Electronic speed drive

assuring acceleration and
deceleration.
 Productivity and Quality Improvement
Application:
Bottle conveyor
Problem: Bottle breakage at
starting.

Solution: Soft starter or

electronic speed drive.
 Mechanics Protection
Application: mechanical stairway
with frequent starts and stops
stressing mechanics.

Solution:
Electronic speed drive
assuring acceleration and
deceleration, limiting torgue jerking.
2- SPEED VARIATION
 Reduced Operating Costs
Application: Ventilation
with airflow variation by
louvre gates causing heavy
consumption.

Solution: Flow regulation

with electronic speed drive.
 Productivity and Quality Improvement
Application:
Timber machine or machining
Problem: Different approach and
machining speeds.

Solution: Produce speed variation using

electronic speed drive.
3- SPEED REGULATION
 Production Constraints
Application:
Cloth reel drying by passage through oven at
constant speed.

Solution:
Produce speed variation using electronic
speed drive (to avoid stretching cloth and to
obtain constant drying time).
4- HUMAN-MACHINE DIALOGUE
 Human-Machine Dialogue and
Speed Control
Application: Machine with mechanical speed variation necessitating stop for human
intervention on speed adjustment.

Solution: Electronic speed drive enables

speed changes:
- without machine stop,
- remotely,
- adapted to process, without human
intervention (regulation, PLC control).
 Electronic Power Control Functions

Starting/deceleration

Speed variation

Speed regulation

Plus integrated automated system functions:

communication, jog, PID, etc.
MECHANICAL LOADS
TORQUE-SPEED
CHARACTERISTICS
Resistive Torque
 Resistive Torque
Cr = Constant Cr = K w

Torque Torque
- Conveyors - Archimedes screw
principle
- Conveyor belts
Speed Speed

2
K
Cr = K w Cr = w

Torque Torque
- Fans - Winders

- Centrifugal - Machine tool

pumps shafts
Speed Speed
Breakaway Torque or Starting Overtorque

Torque
Cr=k2
Cr=k

Cd Cr cst

Cr=k/
Speed

- - - - - - Cd: BRAKEAWAY TORQUE

THREE PHASE INDUCTION
MOTOR
TORQUE SPEED
CHARACTERISTICS
Performance Characteristic of
Induction Motor

Generally, value of reactance magnetization Xm >> value Rm (core

2 2 2
losses) and also X m ( Rs X s )

So, the magnetizing voltage same with the input voltage : Vm Vs

Therefore, the equivalent circuit is ;

Xm
Performance Characteristic of
Induction Motor

Total Impedance of this circuit is :

The rotor current is :
' Vs
Ir 1
2


2
Xm Rr' ' 2
Rs X s X r
S
Performance Characteristic of
Induction Motor
 The Figure above graph shows that starting torque known
as locked rotor torque (LRT) is higher than 100% of the full
load torque (FLT), the safe continuous torque rating.
The locked rotor torque is about 175% of FLT for the example
motor graphed above.
Starting current known as locked rotor current (LRC) is 500%
of full load current (FLC), the safe running current.
The current is high because this is analogous to a shorted
secondary on a transformer.
 As the rotor starts to rotate the torque may decrease a bit for
certain classes of motors to a value known as the pull up
torque.
This is the lowest value of torque ever encountered by the
starting motor.
As the rotor gains 80% of synchronous speed, torque
increases from 175% up to 300% of the full load torque.
This breakdown torque is due to the larger than normal 20%
slip. The current has decreased only slightly at this point, but
will decrease rapidly beyond this point.
 As the rotor accelerates to within a few percent of synchronous
speed, both torque and current will decrease substantially.
Slip will be only a few percent during normal operation. For a
running motor, any portion of the torque curve below 100% rated
torque is normal.
The motor load determines the operating point on the torque
curve. While the motor torque and current may exceed 100% for a
few seconds during starting, continuous operation above 100%
can damage the motor.
Any motor torque load above the breakdown torque will stall the
motor. The torque, slip, and current will approach zero for a no
mechanical torque load condition. This condition is analogous to
an open secondary transformer.
 3 Rr' Vs2
Td

2

X s X r
Rr' ' 2
S ws Rs
S
 NEMA Designs
Characteristics for NEMA designs.
All motors, except class D, operate at 5 % slip or less at full load.
Class B (IEC Class N) motors are the default motor to use in most
applications. With a starting torque of LRT = 150% to 170% of FLT, it can
start most loads, without excessive starting current (LRT). Efficiency and
power factor are high. It typically drives pumps, fans, and machine tools.
NEMA Designs

Examples of machine tools are:

Broaching machine
Drill press
Gear shaper
Hobbling machine
Hone
Lathe
Screw machines
Milling machine
Shear (sheet metal)
Shaper
Saws
Planer
Stewart platform mills
Grinding machines
 NEMA Designs
Class A starting torque is the same as class B. Drop out torque and
starting current (LRC)are higher. This motor handles transient overloads
as encountered in injection molding machines.
 NEMA Designs
Class C (IEC Class H) has higher starting torque than class A and B at LRT =
200% of FLT. This motor is applied to hard-starting loads which need to
be driven at constant speed like conveyors, crushers, and reciprocating
pumps and compressors.
 NEMA Designs
Class D motors have the highest starting torque (LRT) coupled with low
starting current due to high slip ( 5% to 13% at FLT). The high slip results
in lower speed. Speed regulation is poor. Applications include punch
presses, shears, and elevators.

Pd: rcl =1-s :s

CONTROL COMPONENTS
Magnetic Contactors
Electromagnetic Principles
Basic Contactor Operation
Basic Contactor Operation
Basic Contactor Operation
Basic Contactor Operation
Basic Contactor Operation
Coil Symbols
Basic Contactor Operation
Basic Contactor Operation
Three-Phase AC Machines
3 Phase Cage Rotor Starters and Control Gear
Resource 3

Contactor Main pole

terminals 1,
Coil terminals A1 & A2 3&5 Auxiliary contact
terminal 13

Coil

Coil Auxiliary
Main poles
contact

Auxiliary contact
Main pole terminals 2, 4 & 6 terminal 14
Three-Phase AC Machines
3 Phase Cage Rotor Starters and Control Gear
Resource 3

Components of a DOL Starter

Main pole
Contactor
terminals 1,
Coil terminals A1 & A2 3&5 Auxiliary contact
terminal 13

When coil is energised it becomes a

magnet
Coil
Pole contacts closes

Auxiliary contact also closes

Auxiliary contact
Main pole terminals 2, 4 & 6 terminal 14
SOLIDSTATESWITCHING
DEVICES
Current and Temperature
Overloads
Temporary Overloads
Overload Relays
Thermal Overload Relays
Ambient Compensated Thermal Overload
Relays
Three-Phase AC Machines
3 Phase Cage Rotor Starters and Control Gear
Resource 3

Components of a DOL Starter

Overload Unit (Thermal type) When motor overheats due to overload
conditions, main poles latch open
Main pole terminals 1, 3 & 5
Reset
button

N/C
Auxiliary
contacts
95 & 96 Auxiliary contacts also latch open and
N/O
when interlocked within control circuit
Auxiliary
prevents motor restarting by itself when
contacts
cool.
97 & 98

Red pushbutton can be used to reset

Main pole terminals 2, 4 & 6
Three-Phase AC Machines
3 Phase Cage Rotor Starters and Control Gear
Resource 3

Components of a DOL Starter

DOL = Direct On Line
= Direct connection of stator phases to the 3 phase supply

FUSES MCB

Designed to operate very quickly

Protect against short circuit currents to
earth or between phases
Three-Phase AC Machines
3 Phase Cage Rotor Starters and Control Gear
Resource 3

Components of a DOL Starter

Isolator Isolator with integral fuses

Makes circuit dead allowing for maintenance

Should be door interlocked and lockable for safety
Three-Phase AC Machines
3 Phase Cage Rotor Starters and Control Gear
Resource 3

Components of a DOL Starter

Start and Stop pushbuttons
Start button is green and Stop button is red and Emergency Stop button has a
flush mounted protruding red mushroom head which
latches in and must be turned
to release

Contacts at the
back of
switches can
be either N/O
or N/C N/O contact N/C contact
TIMINGRELAY
TIMINGRELAYFUNCTIONS
Three Phase Induction motor
STARTING
Starting
1- DOL
DOL (DIRECT ON LINE)
DOL (DIRECT ON LINE)
 DOL (DIRECT ON LINE)
Start

Stop

Q11
START-STOP
Stop Start Q
1 X 0
0 0 ????
0 1 1
 START-STOP
Stop Start Q-I
Qo
S 3 S2 S1
0-3 1 X X 0
0 1 1 1
4 0 0 0 0
0 0 0 0
5 0 0 1 1
6 0 1 0 1
7 0 1 1 1
 START-STOP
Set Reset
Motor Start=1 Stop=1

start S

stop R
DOL (DIRECT ON LINE)
 START-STOP WITH OVERLOAD
Stop Start Q-I
OL Qo
S3 S2 S1
0-7 1 X X X 0
8-11 0 1 X X 0
12 0 0 0 0 0
13 0 0 0 1 1
14 0 0 1 0 1
15 0 0 1 1 1
 START-STOP
Set Reset
Motor Start=1 Stop=1
Or OL=1

start S

stop OR
R
OL
DOL (DIRECT ON LINE)
DOL (DIRECT ON LINE)
starting
DOL (OVERLOAD BYPASSED)
DOL (DIRECT ON LINE)
 DOL (DIRECT ON LINE)
Start

Stop

Q11

Q14

Timer
starting
STARTOR RESISTORS
AUTOTRANSFORMER STARTER WITH
RESISTORS, 2-STAGE
AUTOTRANSFORMER STARTER WITH
RESISTORS, 2-STAGE
 AUTOTRANSFORMER STARTER WITH
Start RESISTORS, 2-STAGE

Stop

Q11

Q16

Q17
starting
STAR DELTA
STAR DELTA
STAR DELTA
STAR DELTA SWITCH
STAR DELTA
STAR DELTA SWITCH
 Conventional Starters
Direct Starting Star-Delta
Current
Starting
Current

7
7

Idd 6 Idd 6

5
5
Current/speed curves 4
4
3
3
Id 2
2
1
1 Speed
Speed
0 0,25 0,5 0,75 1
0 0,25 0,5 0,75 1 Idd = Direct starting current
Id = Starting current with starter Torque
Torque

2,5 2,5
Cdd = Direct starting torque
Cd = Starting torque with starter
2 Cr = Machine resistive torque 2

Cdd 1,5 Cdd 1,5

Torque/speed curves
1 1

0,5 Cd 0,5
Cr Cr
Speed Speed
0 0,25 0,5 0,75 1 0 0,25 0,5 0,75 1
 Conventional
Stator Resistance
Starters
Autotransformer
Starting Current
Starting
Current
7
7
Idd 6
Idd 6
5
5
Id Current/speed curves
4 4
Id 3
3

2 2

1 1
Speed Speed
0 0,25 0,5 0,75 1 Idd = Direct starting current 0 0,25 0,5 0,75 1
Id = Starting current with starter
Torque Torque

Cdd = Direct starting torque 2,5

2,5
Cd = Starting torque with starter
Cr = Machine resistive torque
2 2

Cdd 1,5 Cdd 1,5

Torque/speed curves
1 1
Cd Cd

0,5 0,5
Cr Cr
Speed Speed
0 0,25 0,5 0,75 1 0 0,25 0,5 0,75 1
Conventional Starter General Characteristics
USE STARTING CURRENT STARTING
CRITERIA TORQUE
Direct starting current
DIRECT - Motor with 3 terminals, low/medium power. Generally at least rated
- On-load starting. Idd = 4 to 8 times
STARTING - High current inrush and voltage drop. torque Tdd = direct
rated current
No parameter setting. starting torque
- Motor with 6 terminals.
- No-load or low torque starting.
- High current inrush and torque at star-delta Id = 1 Td =1
STAR-DELTA
changeover. Idd 3 Tdd 3
STARTING - Equipment requiring maintenance.
No parameter setting.

STATOR - Motor with 3 terminals, high power.

Si U Id = Idd Td = Id 2 = 1
RESISTANCE
-
-
Rising resistive torque starting.
High current inrush. 2 2 Tdd ( )
Idd 4
STARTING - Large, bulky equipment requiring maintenance.
No parameter setting.
- Motor with 3 terminals, high power.
AUTO- - High voltage drop and current inrush at full
Td = 1
Si U
voltage coupling. Idd
TRANSFORMER - Complex and bulky equipment requiring 2 4 Tdd 4
STARTING maintenance.
No parameter setting.
The objective of the starter is to limit current peaks and torque jerking and to take the motor to its rated
state as progressively and smoothly as possible.
Each conventional procedure has advantages and disadvantages.
Electronic starters enable optimisation of starting conditions and parameter setting.
starting
ROTOR STARTERS
ROTOR STARTERS

Q13 Q12
ROTOR STARTERS
starting
SOFT STARTER
 Voltage Ramping with a Soft-Start

Voltage against time graph Torque against speed graph

RMS voltage rises from V0 up to full voltage Torque speed curve rises with voltage
in time tS seconds Not a good method of speed control
 Voltage Ramping with a Soft-Start

Thyristors TH1 and TH2 connected in anti-

parallel

A = anode, K = cathode

L1 supply terminal

T1 motor terminal

Gate terminal used to switch thyristor into

conduction mode.
Thyristor switches off when current reaches zero

RMS voltage control by firing delay of gate pulse

TH1 controls AC wave on positive half cycle, TH2
controls AC wave on negative half cycle
 Voltage Ramping with a Soft-Start

Normal uncontrolled AC wave has RMS

value as shown (=70.7% of peak voltage)
Voltage Ramping with a Soft-Start
Voltage Ramping with a Soft-Start
Voltage Ramping with a Soft-Start
 Voltage Ramping with a Soft-Start

Full voltage supply to motor when there is no delay

 Voltage Ramping with a Soft-Start

Supply terminals L1, L2 and L3 connected via isolator, fuses, main contactor and
overload unit

Motor terminals T1, T2 and T3 connected to motor terminals U1, V1 and W1

 Schneider
Training
Institute
Three-Phase Soft Starter

6-thyristor three-phase installation on resistive and inductive load

Th1
Th'1
R Th1 Th'1 Th1
Th'2 Th2 Th'2 Th2
Th3 Th'3 Th3 Th'3
Th'1
Vm
Vm
Th2 Vm

S M 2
i1 Z

3~ i3 i1 V1
Th'2 i1
2
Th3 0
2

i2
T
V1
i2
Th'3
U Vm
- Vm - Vm
R S T Z
= /3 = 2/3
Th1 Th2 Th3 Th1

Th'2 Th'3 Th'1 Th'2 Example of traces i and v in case where
4
Reproduction prohibited Asynchronous Motor Starting
 Voltage Ramping with a Soft-Start

Commercial Soft-Start
 Schneider Connection Diagram
Training
Institute 1 operating direction, freewheel, manual reset

5
- Q1

1- F1 2 - T1 1- F3 2

13
1- F2 2
- Q1
1

14
- KM1

6
2

4
4/T2 3/L2

6/T3 5/L3
2/T1 1/L1

A1

400/500
C

230
400
- S1

01

02
03

13
KM1 - S2 - KM1

14
27
A1
W1
U1

V1

28
M1

A1
3~ - KM1

Reproduction prohibited Asynchronous Motor Starting A2

SOFT STARTER
 Soft Starter
From stop to steady state speed
Direct on network With ALTISTART

Q1 Q1

KM KM

Starter
Rth with integrated
thermal protection

3 3
~ ~
Speed Speed

Adjustable
starting time

Time Time
 Compatibility with Mechanics

FAN CONVEYOR
C C

at Un Cr = K N2 at Un
Cr = K

at 0.8 Un at 0.8 Un

at 0.5 Un at 0.5 Un
N

0 N3 N 2 N1 0 N
SOFT STARTER
SOFT STARTER
SOFT STARTER
starting
SOLID STATE DRIVE
V/F CONTROL
V/F CONTROL
QUADRATIC V/F CONTROL
 Pulse Width Modulation (PWM) Converters

um
im
Rectifier bridge Pre-load Filter Inverter
R S T

D1 D2 D3 T1 T3 T5

R
M
S C
3~
T

D4 D5 D6 T2 T4 T6

Rectifier Rectified voltage PWM control

Filter Smooth voltage

Inverter Production of AC 3-phase supply varied in frequency and voltage

 Frequency Ramping with an Inverter

Inverter Output waveform Average

voltage is
near
sinusoidal

PWM wave

PWM = Pulse Width Modulation

Average voltage is sinusoidal

Filter is needed to remove harmonics due to chopping

 Frequency Ramping with an Inverter

Commercial Inverter
Adjustments made on a front panel menu
include:-
Maximum frequency

Ramp up time

Method of stopping

Motor can be started and stopped locally

from the front panel or remotely from
external signals

Speed can be adjusted using front panel or

remotely from external signals
Frequency Ramping with an Inverter
Frequency Ramping with an Inverter
UMC100
N
How are UMCs used
PTC 120 / 230 VAC max. 1000 VAC

M
M

1 2 3 4 5 6 7 8 9
T T Ca Cb DO DO DO DO DO
1 2 C C 0 1 2

FieldBus
Plug UMC100

0 24 DO DI DI DI DI DI DI
V V 3 0 1 2 3 4 5
10 11 12 13 14 15 16 17 18

CEM11
Earth Fault Sensor

0V +24V Start Stop

Power
supply
Fault Local
M

ABB Group
10/3/17 | Slide 117
UMC100 Communication
Ethernet Redundant ring topology new
The ring topology offers
cable redundancy on
Ethernet side
A managed switch
supporting MRP and
acting as MRP manager
must be used in this case
The implemented media
redundancy protocol
(MRP) is according to
EN/IEC 62439-2

ABB
March 2012 | Slide 118
Braking
1- PLUG BRAKING
 Plug Braking

Power Schematic same as

reversing DOL starter

Two phases are swapped over

until motor stops.

A centrifugal switch, speed

sensing relay or timer used to
prevent the motor from reversing.

Contactor C2 is for starting

Contactor C3 is for stopping

WARNING
Four times the kinetic
energy of load dissipated Power Schematic
in stator windings
 DC Injection Braking

Power Schematic requires DC available at a lower voltage e.g. 50V

This can be achieved using a transformer and 4 diodes

When required to stop, DC is connected to two of the phases

Stator field then becomes stationary

Rotor then runs faster than stator field causing a large braking torque in the
rotor

When rotor stops there is no more braking torque

WARNING
Control circuit will be the same as for plug braking with timer, DC injection braking
centrifugal switch or speed sensing relay can burn out the
stator windings
Inverters often incorporate this type of braking
 DC Injection Braking

Run contactor C2 will

start the motor as for
DOL starter

When C3 energises,
DC is injected into 2
phases of stator for a
short time

WARNING
DC injection braking
can burn out the
stator windings if
voltage is too high
Power Schematic
 DC Injection Braking

Transformer reduces
AC voltage

Transformer requires
separate fuses

Full-wave rectifier
converts AC into DC

Power Schematic DC section

 DC Injection Braking

DC current travels
through one phase
and back up through
another phase

Power Schematic DC injection

 DC Injection Braking

Press S2 to start
as for DOL starter

Press S1 to stop
as for DOL but C3
will energise for a
time
WARNING
DC injection braking
can burn out the
stator windings if time
is too long

This control circuit can

be used for PLUG
braking also Control Circuit
 Speed Ramping Down with an Inverter

Inverter required to ramp the frequency of motor supply down to zero

Stator field moves slower that rotor causing

braking torque

Ramp down time can be adjusted within the

inverter
Speed Ramping Down with an Inverter
 Schneider
Training
Institute
Voltage Wave Converter Braking
Modulated
Rectifier bridge Filter Inverter

D1 D2 D3 T1 T3 T5
Braking
L1
Tf
M
L2 PA C
L3
3~

D4 D5 D6 PB T2 T4 T6

Load
Rf: Braking
resistance Rf Energy dissipation
in a resistance

Braking module

Reproduction prohibited Asynchronous Motor Speed Variation

 Schneider
Training
Institute
Voltage Wave Converter Braking

Modulated
Rectifier bridge Filter Inverter

D1 D2 D3 T1 T3 T5

L1 M
L2 C
L3 3~

D4 D5 D6 T2 T4 T6

Load

TM1 TM2 TM3 Energy feedback to network

Braking inverter
TM4 TM5 TM6

Reproduction prohibited Asynchronous Motor Speed Variation

Speed Variation
1- SPEED REVERSAL
Three-Phase AC Machines
3 Phase Cage Rotor Starters and Control Gear
Resource 3

3-phase
supply
DOL Starter
Power Schematic Fuses

Isolator

Contacto Auxiliary
r contact
C1 (retainer)
Overload Auxiliary
Unit contact
OL1 (interlock)

Safety earth
Induction
Motor
Three-Phase AC Machines
3 Phase Cage Rotor Starters and Control Gear
Resource 3

DOL Starter

Control Circuit

Starting
Press S2
C1 coil energises
Contact C1 retains
S2 can be released

Stopping Faults
Press S1 breaks circuit Overload causes OL1 to open
C1 coil de-energises C1 coil de-energises
C1 retaining contact C1 retaining contact drops out
drops out
Three-Phase AC Machines
3 Phase Cage Rotor Starters and Control Gear
Resource 3

Power Schematic
Three-Phase AC Machines
3 Phase Cage Rotor Starters and Control Gear
Resource 3

Control Circuit
Reversing
Starting - Forward
DOL
Press S2 Starter
C2 coil energises
Contact C2 retains
S2 can be released
Electrical interlock with
C3

Starting - Reverse
Press S3 Stopping Faults
C3 coil energises Press S1 breaks circuit As for DOL
Contact C3 retains C2 or C3 coil de-energises
S3 can be released C2 or C3 retaining contact drops
Electrical interlock with C2 out
Three-Phase AC Machines
3 Phase Cage Rotor Starters and Control Gear
Resource 3
Speed Variation
2- ROTOR RESISTANCE
 Motor Operation

The Rheostat Method of Starting

1. Motor starts with 3-gang

Rheostat set to highest
resistance giving low starting
current and slow speed.

2. The Rheostat is adjusted

slowly thus reducing rotor
resistance to zero.

3. This increases rotor speed

up to its maximum value

4. Starting torque can be

easily adjusted by initial
resistance setting to suit the
load.
 Motor Operation

Stator Connections
The Contactor Method of Starting

1. Motor starts with 3 Earth Terminal

resistors in each rotor circuit Shorting Relays K1, K2, K3
giving low starting current and Rotor Connections
slow speed.
2. K3 is energised shorting
Rotor Resistor
out resistors R31, R32, R33 Bank 1
giving increased speed.
3. K2 is energised shorting
out resistors R21, R22, R23 Rotor Resistor
giving increased speed. Bank 2

4. K1 is energised shorting
out resistors R11, R12, R13
giving full speed. Rotor Resistor
Bank 3
 Motor Performance

Torque-Speed Curve for a

four pole motor

Increasing Rotor Resistance

1. Does not change synchronous

speed

2. Does not change maximum

torque

3. Increases Starting Torque

4. Decreases Speed in running

region for given load

5. Decreases Speed where

maximum torque occurs

6. Decreases Starting Current

 Te

Pull out
Torque Intersection point
(Tmax) (Te=TL) determines the
Te
steady state speed

TL
Trated

wr
sm ww w
s rated rotor s
 Scalar control of induction machine

Tm-Tload=J w
Te
Te
Intersection point
(Te=TL) determines the
steady state speed

TL

wr
w w w w w w w
s5 s4 s3 s2 rotor s
s4 w s4
 Scalar control of induction machine

Te
Te
Intersection point
(Te=TL) determines the
steady state speed

TL

wr
w w w w w w w
s5 s4 s3 s2 rotor s
s4 w s4
Speed Variation
3- DAHLANDER MOTOR
POLE CHANGER
Dahlander motor
Dahlander motor
Dahlander motor
Dahlander motor
Dahlander motor
Dahlander motor
Dahlander motor
Dahlander motor
Dahlander motor
Dahlander motor