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T6- Basic AC Motor Control

Electrical Technology (Politeknik Sultan Abdul Halim Mu'adzam Shah)

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BASIC MOTOR CONTROL

Definition of motor control
Motor control is a combination of devices for turning on, turning off and controlling the speed of a
motor that can be controlled from the desired distance and also at set times.
The induction motor when turned directly from the supply, it will take a high starting current
between 5 to 7 times the full load current and the torque produced is only about 2 times the full
load torque. For motors with large rated capacity direct switching must be avoided because high
starting currents can cause a large line voltage drops, this condition will affect electrical equipment
connected to the same line power supply.

The following are the main functions of a motor starter.

• Turn on the motor safely.

• Turn off the motor safely.
• The need for the motor to change the direction of time.
• Provide protection against motor overvoltage and Undervoltage.

There are two basic types of controllers: electronic and electromechanical.

Electronic units are very sophisticated and include features such as soft starting and variable
frequency drives. Electronic units can be programmed to respond to system inputs and pre-set
running conditions.
Electromechanical units make use of electromagnetic contractors or relays to stop, start, and
reverse the motor's direction.

TYPES OF MOTOR CONTROL

i- Manual control - is used to turn the motor on and off, for small motors only. The control is
operated by hand at the control point itself.
ii - Semi auto - Controls that use a magnetic contact that is controlled by one or more devices
such as floating switch, limit switches and others.
iv – Automatic control - A control that uses a magnetic touch controlled by one or more
automatic pilot devices.

MOTOR CONTROL EQUIPMENT

1- Push Button

Pushbuttons are momentary contacts that come available as either normally open (NO) or
normally closed (NC) contacts, although many pushbuttons come with both NO and NC
sets of contacts. When you depress the button, you change the state of the contacts, and
when you release the button, a spring returns the contacts to their original state.

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2- i) Magnetic Contactor – There are two types of contact it is Main Contacts and Auxiliary
Contacts.

Contactors are used for high-current load applications, work

on the principle of electromagnetic attraction. Generally used
in power circuits to get on /off control for the operation of the
machines or motors. Installed on the main circuit only.

ii) Auxiliary Contactor

Auxiliary contactor it is used to connect or disconnect the circuit to control a power

contactor. Consists of normally open and normally close. Installed in the control circuit only.

3- Over Load Relay (TOR)

An overload relay is one such device that protects a motor from damage caused by overload
and excess current. It is used with a contactor and can be found in the motor control section or
motor starter.

4- Timer Delay Relay (TDR)

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Function of Time Delay relay (TDR) is a timer for controlled equipment. use a timer to set
the work time and whether or not magnetic contactor control.

5. Circuit Breaker

single phase C.B 1P

three phase C.B 3P

A Motor circuit breaker is a device integrating Low voltage circuit breakers. This device
is capable of protecting the motor branch circuits from overload, phase-loss, and short-
circuit alone. It enable even more secure wiring and motor protection.

6. Auto Transformer

At the time of starting, a reduced voltage is applied across the motor through the tappings of the
autotransformer. The motor gets a lower starting voltage according to the selection of the
tapping. Also, the motor draws less starting current and develops less starting torque
accordingly.

7. Rotor Resistance

In a rotor resistance starter, a star connected variable resistance is connected in the rotor circuit
through slip-rings. The full voltage is applied to the stator windings.

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8. Indicator Lamp

Multiple lamps to indicate the state of operation of the circuit. - Green or yellow indicates t the
circuit is running in a normal mode. - Red indicates that there is an overload or tripping in the
circuit.

MOTOR PROTECTION

MCB A circuit breaker is an electrical switch designed to protect

an electrical circuit from damage caused by
overcurrent/overload or short circuit.
Isolation Switch used so that the motor can be disconnected from the
supply. This is to facilitate safe repair or inspection work. It
is best installed in a place that is easily visible and in the
"off" state it can be locked.
TOR they are designed to cut power if the motor draws too much
current for an extended period of time which will damage
the motor. For this purpose TOR is used.
Contactor When the supply is disconnected the motor will stop and
when the supply is restored the motor will not turn on
immediately unless the switch is "on" again. The reason is
for motor and user safety. The use of this contactor is
known as no -load protection.

AC MOTOR STARTER
This starter is used to protect a motor from the dangers of high currents when the motor is first
turned on. According to IEE 552-4 regulations each motor shall have the following control devices
for the safety of the motor and the user among others…
i) Stopper and starter control.
ii) No voltage protection
iii) Overload protection
iv) And isolation switch.

TYPES OF A.C. MOTOR STARTERS :

i) Direct Online Starter (DOL), 0.5Hp- 3Hp
ii) Forward-Reverse Starter, 0.5Hp-3Hp
iii) Star-Delta Starter, 3Hp-10Hp
iv) Autotransfomer Starter, 10Hp - 25Hp
v) Rotor Resistance Starter, 25Hp - and above.
vi) Soft Starter

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1- Direct On-Line Starter

- When the START Button is pressed, the magnetic coil (C1) receives the supply pulling the main
contactor ON and the supply will reach the motor through the main circuit.
- When the START Button is released, current flows through an auxiliary contact that is
synchronized with the START Button.
- The STOP Button is connected in series with a magnetic coil (no volt coil) and when this button is
pressed the supply will be cut off, the pulling power will be lost and main contacts will return to
their original position.

2- Forward Reverse Starter

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- When the PB1 pushbutton is pressed, the coil F will receive electrical energy. The contact
F normally-open (N/O) will close while the F normally-close (N/C) will open. The motor
will rotate forward.
- When the PB 3 push button is pressed, coil F will lose electrical energy. The motor stops
rotating.
- When the PB2 push button is pressed, the coil R will receive electrical energy. The contact
R normally-open (N/O) will close while the R normally-close (N/C) contact will open. The
motor will receive electrical energy and rotate in the opposite direction.
- To stop the motor, the PB3 pushbutton must be pressed.

3- Star-Delta Starter

- When PB START is pressed, contactors M, S and Timer are energized.

- At the same time contact M1 (N/O) will be closed as well as contact S1 (N/C) will be
open. The motor runs only with a STAR connection.
- Once the timer reaches the adjusted time, the timer contacts will open and cause the
STAR coil de-energized. At the same time this timer contact moves part of the DELTA
circuit and the previously contact S1 is open (N/O) will be closed again.
- Then current will flow from contactor M to contactor D and contactor D is energized. At
the same time contact D1 (N/O) will be closed and contact D2 (N/C) will be open and
cut off the STAR contactor even if the TDR returns to the origin. The motor runs only
with a DELTA connection.
- To stop the motor running, Button STOP must be pressed.

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4- Roto Resistance Starter

Rotor Resistance Starter it consists of 3 resistances connected in series with the rotor windings,
thus reducing the rotor current, but increasing the torque. During the motor start, these resistances
are kept at maximum position such that a reduced voltage is applied across the motor due to large
voltage drop across resistances.
Once the motor picks up the speed, the resistance connected to each phase is gradually reduced
from the stator circuit. When these resistances are removed from the circuit, a rated voltage (full
voltage) is applied to the motor and hence it runs at rated speed.
In this method, it is important to maintain the starting torque to the motor while minimizing the
starting current. This is because current varies in proportion to the voltage whereas the torque
varies square of the applied voltage. Suppose if the applied voltage is reduced by 50 percent, the
current will be reduced to 50 percent while the torque reduced by 25 percent.

5- Autotransformer Starter

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• Starters Autotransformers are popular starters used to limit voltage and when we need
starting torque adjustment for 3-phase motors carrying loads of different capacities.
• These starters are typically used to start medium-sized and maximum motors up to 75 kw.
• This adjustment of the starting torque can be done by reducing the voltage supplied to the
motor through the taps of the auto transformer which is matched to the capacity of the load
to be rotated.
• The voltage connected to the stator coil, can be reduced to a few percent when it is
connected in a star. Indirectly this method can also reduce the starting current of the motor
and the motor will rotate safely according to its load capacity.
• During the initial stage, the step down auto transformer is the primary winding connected to
the supply and on the secondary side the winding is connected to the stator winding.
• Transformer tapping values (e.g. 40%, 60%and 75%), this allows us to make a choice of
voltage or current values specifically for starting purposes.

Examples of Auto Transformer Usage

- Suppose a 415V three -phase induction motor, takes a current of 160A, when connected to
a D.O.L starter .
- If an auto transformer is used as a starter, where it is connected at 70% output to start the
motor, find:-

- Motor starting voltage ?

For 70% production.

Motor voltage starting = 70% x Input Voltage

= 70% x 415V
= 0.7 x 415 V
= 290.5 Volt

- Starting current ?
For 70% motor production.
Motor current = 70% x D.O.L Input current
= 70% x 160A
= 0.7 x 160 A
= 112 AMP

- Line Starting Current ?

V1 I1 = V2 I2
I1 = V2 I2 / V1
= (290.5 V x 112A) / 514V
= 78.4 AMP

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