Overview of LV Motor starters

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 Basic Motor Starter
Motor Starter Theory

Outline

„ What are LV motor starters?

„ What are the different configurations of motor starters?

„ What are the common conventional starting methods?

„ Coordination of motor starter elements.

„ Overload tripping classes.

„ Questions

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 Basic Motor Starter
Motor Starter Theory

Torque characteristics for different Applications

TR = Constant TR = Kω
Torque Torque

- Conveyors -Principle of the

Archimedes screw
- Belt
conveyors Speed Speed

TR = Kω 2 K
TR=
ω
Torque Torque
-Fans -Winders
-Centrifugal -Spindles of
pumps Speed
machine tools
Speed

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 Basic Motor Starter
Motor Starter Theory

Motor types

Motors

DC Motors AC Motors Stepper Motors Servo Motors

Induction motor Sychronus motor

Squirel cage Slip ring

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 Basic Motor Starter
Motor Starter Theory

Characteristics of asynchronous motors

Type of Motor Advantages Disadvantages

Standard Starting torque
Simple Starting Current
Maintenance Free
Squirrel Cage
Cabling
Price

Price
Starting torque
Slip Ring Starting Current Cabling
Maintenance

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 Basic Motor Starter
Motor Starter Theory

Squirrel Cage Motor

„ Used in the majority of industrial applications

End shield ventilator side

„ Simple, economical & rugged motor

Bearing
Mounting rod

Ventilation
Fan
cover
Stator

Cage rotor
Bearing Easily
Easilydamaged
damagedparts
parts
End shield shaft end side

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 Basic Motor Starter
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Associated functions to load switch

Low voltage distribution

Isolation Isolate equipment from electrical supply

Disconnection Interrupt current through equipment

Short circuit protection Protect against human and material damages

Overload protection Protect motors against overload current effects

Switching ON / OFF loads

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 Basic Motor Starter
Motor Starter Theory

The load break switch / isolator

„ This device has disconnection and isolation capability

„ Can be used safely « on load »

„ It does not include any protection mechanism

„ May be used as an emergency stop button (with yellow cover

and red handle)

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 Basic Motor Starter
Motor Starter Theory

The Magnetic Circuit Breaker

„ Device which provides short-circuit protection with omnipolar

current break. It detects and break high levels of short circuit
currents up to the limit of their breaking capacity.

GV2-L
„ Has disconnection capability
GV2-L
„ Reset after fault can be done manually by operating the rotary
switch, or remotely using optional module

„ For relatively low fault currents, the operation of a circuit

breaker is faster than that of fuses

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 Basic Motor Starter
Motor Starter Theory

The Magnetic Thermal Circuit Breaker

„ This circuit breaker includes both magnetic protection against

short circuits, and thermal protection (motor overload)

„ Since it includes all types of protection and has disconnection

capability, it can be used as a motor starter for simple
machines.

GV2-ME
„ Optional blocks can be added to enable remote reset and
control of the circuit breaker.

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 Basic Motor Starter
Motor Starter Theory

The Contactor

„ Makes and breaks current on loads – Switching capacity

„ Operated remotely using an electromagnet and a separate

LC1-D control circuit
contactor
„ When the coil of the electromagnet is energized, the mobile
part of the contactor moves and current can flow from the
supply network to the load.

„ Auxiliary contacts are included and moving simultaneously

with the mobile part of the contactor

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 Basic Motor Starter
Motor Starter Theory

The Thermal Relay

„ Overload is the most common fault on machines

„ Overload creates an increase in current drawn by the load

and leads to dangerous overheating of the load.

LRD Relay
„ Overheating can affect the isolating materials and thus the
lifetime of the motor

„ The relay is made of 3 bimetal elements, each being

surrounded by a heating coil carrying its phase current.

„ As the motor draws current, the bimetal will bend and the
amount of bending is linked to the level of current

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 Basic Motor Starter
Motor Starter Theory

The Combined Motor Starter

„ In 1983, Telemecanique introduced the first device capable of

disconnection, switching and thermal-magnetic protection : the
INTEGRAL
Integral

„ This type of product offers all motor starting functions in one

product

„ Provides total coordination : no contacts welding after short-

circuit, reduced maintenance operation

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 Basic Motor Starter
Motor Starter Theory

Associated functions to load switch

Low voltage distribution

Isolation
Switch Disconnector
Disconnection TeSys VARIO

Short circuit protection

Overload protection

Switching

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 Basic Motor Starter
Motor Starter Theory

Associated functions to load switch

Low voltage distribution

Isolation
Motor Circuit Breakers
Disconnection TeSys GV

Short circuit protection

Overload protection

Switching

IEC 60 947- 2
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 Basic Motor Starter
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Associated functions to load switch

Low voltage distribution

Isolation Contactors
TeSys K
Disconnection TeSys D
TeSys F
Short circuit protection
Bar Contactors
Overload protection

Switching

IEC 60 947- 4 -1
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 Basic Motor Starter
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Associated functions to load switch

Low voltage distribution

Isolation Power
Motor Starters
Disconnection

Short circuit protection

Overload protection

Switching Control

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 Basic Motor Starter
Motor Starter Theory

D.O.L* Starting

„ Available starting current = 100%

„ Peak starting current = 4 to 8 In
„ Peak starting torque = 0.6 to 1.5Tn

Advantages : Typical applications:

† Simple starter
Small machines, may often
† Low cost
be started on full load
† High starting torque

Disadvantages :
† Very high starting current and torque
† Supply must withstand peak current
† Mechanically harsh starting sequence
* Direct On Line
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 Basic Motor Starter
Motor Starter Theory

Asynchronous Motor D.O.L.* Start

„ The most frequently used solution

„ The most economical and simple solution

„ Non smooth start (not for elevators, escalators,…)

„ The unique start method which does not reduce motor torque
(except with an electronic variable speed controller)

* Direct On Line

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 Basic Motor Starter
Motor Starter Theory

Asynchronous Motor D.O.L. Start

Control and
Protection
during starting
phase
Control and
Protection
Load torque during
maximum running
Rated zone during phase
Torque
Load torque maximum zone running
during starting phase phase

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 Basic Motor Starter
Motor Starter Theory

Asynchronous Motor Star - Delta Start

„ Available starting current = 33%

„ Peak starting current = 1.3 to 2.6 In
Typical applications:
„ Peak starting torque = 0.2 to 0.5 Tn
Machine starting on no load
Advantages : (small centrifugal pumps,
fans, etc.)
„ Simple economic starter
„ Good starting torque, current performance

Disadvantages :
„ Low starting torque
„ Non adjustable starting parameters
„ Break in supply to motor leads to severe transient
peak current

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 Basic Motor Starter
Motor Starter Theory

Asynchronous Motor Star - Delta Start

• The motor is initially

connected in star
configuration and then, after
Main Delta a preset time, the motor is
Contactor Contactor
disconnected from the supply
Thermal and reconnected in delta
Overload
configuration.
Motor
3~ • The current and torque in
the star configuration are one
third of the full voltage current
and torque when the motor is
Star
Contactor connected in delta.

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 Basic Motor Starter
Motor Starter Theory

Asynchronous Motor Star - Delta Start

„ Limited peak of current (1.3 to 1.6x In)

„ specific motor (coupling change capability)

„ Machines presenting low torque on starting

† fans, compressors with exhaust to air

„ Transient currents can be high on changeover to delta if the

wiring diagram and phase sequence are not scrupulously
observed.
† If star time delay too short, start becomes similar to direct-on-
line start.
† If the resistive torque is higher than the maximum the output
torque in star connection, the motor will stall.

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 Basic Motor Starter
Motor Starter Theory

Asynchronous Motor Star - Delta Start

I(A) „ Is: DOL start current

Is
T (Nm) „ Is/3: start current under star
connection
„ Ts: DOL start torque
„ Ts/3: start torque under star
connection
„ Tr: resistive torque (load)

Ts
Is/3

Ts/3
Tr
Star Delta n (rpm)

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 Basic Motor Starter
Motor Starter Theory

To sum up and start a Motor Correctly...

„ Always, Motor torque > resistive torque (extremely important
for Star - Delta)
† Otherwise will cause the Rotor Stall
† Or Jam

„ Current intake so that Delta Voltage on the line is < 10%

† Too much voltage drop will lead to over current and over load

„ Start time corresponds to thermal capabilities of the motor

„ AC-3 contactor, rated motor current and capable of

withstanding start current during the start time

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 Basic Motor Starter
Motor Starter Theory

Overview of the Motor Failure

10%
5% 12%

Over Load
10% Moisture
18%
Contamination
Aging
Single Phasing
Bearing
10% Miscellaneous

35%

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 Basic Motor Starter
Motor Starter Theory

The Motor Should be Fully Protected

„ 1. Thermal overload is the basic protection function
† Temperature sensor is an add-on to the functionality
„ 2. Advanced protections
† Current based faults
– Phase Current Imbalance, Phase Current Loss, Ground Current
– Over Current, Under Current, Long Start, Current Reversal
† Voltage based faults
– Phase Voltage Imbalance, Phase Voltage Loss, Phase Reversal
– Over Current, Under Current
† Power based faults
– Over Power, Under Power, Over Power Factor, Under Power
Factor

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 Basic Motor Starter
Motor Starter Theory

Why of Phase Reversal Protection?

„ Possible Causes
† Connection mistake
† Problem of upstream power supply

„ Risks
† Motor direction reversed (start stage)
† Motor change direction without transition time
† Damage to people and the load equipment

„ Solutions
† Current Phase Reversal detection and protection - when motor is
running
† Voltage Phase Reversal detection and protection when motor is
stopped

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 Basic Motor Starter
Motor Starter Theory

Why of Underload Protection?

„ Possible causes
† Many applications (particularly those related to pumps) require the monitoring
of load loss.
† Cause from the side of the load
– Also broken belts, chain, couplings etc...

„ Risks
† The risk is on the equipment instead of the motor itself
† Under-load will cause a very high speed, which will lead to the damage of
some equipment
† Cavitation

„ Solutions
† Under-load protection through current, power or power factor
† Under-load protection through “power factor” is extremely important for small
motor - sometime the other parameters cannot show this condition

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 Basic Motor Starter
Motor Starter Theory

Coordination of protective devices

International/Europeans norm : IEC/EN 60947-X
Products... Standards
All 60947-1 General rules of electrical products
GV 60947-2 Circuit breakers
LS, GS 60947-3 Switch and fused switch disconnectors
GV, LC,LR 60947-4-1 Contactors et motor starters
LH4 60947-4-2 Starters with semi-conductors
….. 60947-4-3 Contactors and graduators other than motors
Sensor,Aux. 60947-5-.. Control circuit switchgear replacing IEC 337
NS 60947-6-1 Equipment for connection via automatic transfer
LD,LU 60947-6-2 Equipment for connection with multiple functions
AB 60947-7 Junctions blocks
LT3S 60947-8 Relays with probe
The 60947-6-2 norm groups together the starter motor function. It guarantees with only one
product all the functionality of starter controller without error of association...
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 Basic Motor Starter
Motor Starter Theory

Categories of use According to IEC-947

AC-1: AC-3:
Resistive loads and slightly inductive Squirrel cage induction motors. The
loads (p.f. >0.95) starting current is 7-8 times the rated
current.

AC-2: AC-4:
Slip ring induction motors. The Squirrel cage induction motors. The
starting current is 2.5 times the rated starting and breaking currents are 7-8
current. times the rated current.
.

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 Basic Motor Starter
Motor Starter Theory

Coordination of protective devices

„ Contactors and motor starters

Time
† Coordination with short-circuit protection devices
2h
1h
Overload protection
30min
Breaking capacity
of the contactor
10min
5min
Short circuit protection

2min
1min
20s
10s Thermal withstand of
overload protection device
5s
Starting without any damage
2s
1s
1 2 3 4 5 6 8 10 17 In Current K x Ie

Normal overload Rotor locked Short-circuit

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 Basic Motor Starter
Motor Starter Theory

Motor circuit breaker tripping curve

T(s)

10 000

Motor
starting 1 000

100

Distribution 10

line protection
1

0,1

Tripping due to
GV protection 0,01
starting inrush

0,001 13 x Ir k x Ir
7,2 x Ir

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 Basic Motor Starter
Motor Starter Theory

Coordination of protective devices

„ Effects of a short-circuit

† Electrodynamics effects of peak current î:

– repulsion of contacts
– propagation of electrical arcs
– damage to isolation equipment and deformation of parts

† Thermal effects l²t:

– fusion of contacts
– generation of electrical arcs
– heat damage to isolation equipment

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 Basic Motor Starter
Motor Starter Theory

Coordination of protective devices

„ Definition
† Testing of the products in extreme conditions. The starter combination should be
able to clear the current fault quickly, without any damage to the installation or risk
to personnel.
„ Without coordination
† The risks are important for the personnel, the physiques and materials damages
can be also important.
„ Type 1 coordination
† Without risk for the operator. It is the most standard solution used.
† Before to restarting, the replacement of parts can be necessary.
„ Type 2 coordination
† It is the high performance solution. The risk of fusion of contacts is possible. In this
case, the contacts must be easier separated.
„ Total coordination, continuity of service
† It is the higher performance solution.
† No damage and no risk of fusion. Once the fault has been fixed, the motor starter
must be able to restart immediately.

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 Basic Motor Starter
Motor Starter Theory

Coordination types: NO Coordination

Isolation
I>> Protection
GV2ME / RS
Thermal Overload Protection
+
LC1 Command

t
GV2 ME/RS Trip curve

LC1 breaking capacity (IEC 947-4)

Welding curve of contacts

Starting Current

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 Basic Motor Starter
Motor Starter Theory

Coordination types: Coordination Type 1

Isolation
I>> Protection
GV2ME / RS
Thermal Overload Protection
+
LC1 Command

t
GV2 ME/RS Trip curve

LC1 breaking capacity (IEC 947-4)

Welding curve of contacts

Starting Current

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 Basic Motor Starter
Motor Starter Theory

Coordination types: Coordination Type 2

Isolation
I>> Protection
GV2ME / RS
Thermal Overload Protection
+
LC1 Command

t
GV2 ME/RS Trip curve

LC1 breaking capacity (IEC 947-4)

Welding curve of contacts

Starting Current

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 Basic Motor Starter
Motor Starter Theory

Coordination types: Total Coordination

Isolation
I>> Protection
TeSys U
Thermal Overload Protection
Command

t
TeSys U Trip curve

breaking capacity (IEC 947-6)

Never Welding
Starting Current

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 Basic Motor Starter
Motor Starter Theory

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 Basic Motor Starter
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 Basic Motor Starter
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Tripping class
„ Definition
† The class define the tripping time to 7,2 Ir ; the selection is depending
to the nature of the application.

Class 10A 2 < Tp <= 10s

Class 10 4 < Tp <= 10s
Class 20 6 < Tp <= 20s
Class 30 2 < Tp <= 30s

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 Basic Motor Starter
Motor Starter Theory

Simply Smart
products are going
to amaze you ! T hanks
for your attention

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