Motor Start Theory

ME00107A
Induction Motors Have Two
Prime Functions

To convert electrical energy into

mechanical energy in order to
accelerate the motor and load to
operating speed Starting Function

To convert electrical energy into

productive work output from the
machine Work Function
Motor Performance
Motors consist of two major sections The Stator and the Rotor

The stator consists of magnetic poles and stator windings within the
frame of the motor.By variation of winding configuration and the
contour of the stator laminations , the full load characteristics are
determined
The motor speed is determined by the number of poles

The rotor consists of a cylindrical short-circuited winding around iron

laminations The rotor design affects starting performance.
The shape, position and material of the rotor bars affect the current
drawn and torque produced during motor starting.
Motor Performance

Full load characteristics are well

understood with factors such as motor
speed,torque and efficiency being the
typical selection criteria.

A motors start performance

characteristics are usually the least
understood but set the limits of what
can be achieved with either a full
voltage or reduced voltage starter.

It is especially important to consider

motor start characteristics when
seeking to:
- Minimise start current
- Maximise start torque
Typical Motor Data Sample Of Typical 110kW Motors
A motors start performance Motor Speed FLC LRC LRT % FL Torque
(rpm) (amps) (%FLC) (%FLT) Efncy @3xFLC
can be identified by examining
the motor data sheet. A 1470 191 600 263 93 65.8
B 1475 184 600 190 93.5 47.5
The table details selected
C 1475 191 570 150 92 41.6
performance data for a range
of 110kW motors. D 1480 187 660 190 94.5 39.2
E 1470 185 550 120 92 36
F 1470 191 670 150 93 30.1
G 1480 190 780 200 94 29.6
H 1475 182 850 220 93.5 27.4
I 1480 190 670 120 94 24
Start Current
The motor performs as a Sample Of Typical 110kW Motors
transformer with current Motor Speed FLC LRC LRT % FL Torque
induced in the rotor by the flux (rpm) (amps) (%FLC) (%FLT) Efncy @3xFLC
in the stator. A 1470 191 600 263 93 65.8

Maximum motor start current B 1475 184 600 190 93.5 47.5
under full voltage start C 1475 191 570 150 92 41.6
conditions is defined by the
motors Locked Rotor Current. D 1480 187 660 190 94.5 39.2
(LRC) This is when the rotor E 1470 185 550 120 92 36
is stationary
F 1470 191 670 150 93 30.1

LRC levels vary considerably G 1480 190 780 200 94 29.6

between motors H 1475 182 850 220 93.5 27.4
I 1480 190 670 120 94 24
In the example, Motor H will
draw 55% more current at
start than Motor E.
LRC ranges from 550% to 850%
 Torque-Speed Characteristic

The Torque Speed Curve shows how the

motors torque production varies throughout the
different phases of its operation.

Starting Torque (LRT) is produced by a motor

when it is initially turned on. Starting torque is
the amount required to overcome the inertia
from standstill.

Pull-up Torque is the minimum torque

generated by the motor as it accelerates from
standstill to operating speed. If the motors pull-
up torque is less than that required by its
application load , the motor will overheat and
eventually stall.
 Torque-Speed Characteristic

Breakdown Torque is the

greatest amount of torque a
motor can attain without stalling.

Full Load Torque is produced

by a motor functioning at a rated
speed and horsepower.

Synchronous speed is the

speed at which no torque is
generated by the motor.This
only occurs in motors that run
while not connected to a load.
Start Torque
Motor start torque performance
Sample Of Typical 110kW Motors
is indicated by the motors Motor Speed FLC LRC LRT % FL Torque
Locked Rotor Torque (LRT) (rpm) (amps) (%FLC) (%FLT) Efncy @3xFLC
figure. A 1470 191 600 263 93 65.8
B 1475 184 600 190 93.5 47.5
This is the measured torque with
the rotor locked and the rated C 1475 191 570 150 92 41.6
voltage and frequency applied to
D 1480 187 660 190 94.5 39.2
the motor.Torque is a product of
force and the radius at which it is E 1470 185 550 120 92 36
applied and is measured in Nm. F 1470 191 670 150 93 30.1

LRT levels vary considerably G 1480 190 780 200 94 29.6

between motors. H 1475 182 850 220 93.5 27.4
In the example, Motor A
I 1480 190 670 120 94 24
produces twice as much torque
during start as Motor I.

LRT ranges from 120% to 263%

LRC & LRT Work
Sample Of Typical 110kW Motors
Together
Motor Speed FLC LRC LRT % FL Torque
(rpm) (amps) (%FLC) (%FLT) Efncy @3xFLC
LRC & LRT must be A 1470 191 600 263 93 65.8
considered together when
determining a motors start B 1475 184 600 190 93.5 47.5
performance. C 1475 191 570 150 92 41.6

The example does this by D 1480 187 660 190 94.5 39.2
ranking the motors according E 1470 185 550 120 92 36
to the torque produced at
F 1470 191 670 150 93 30.1
3 x FLC.
G 1480 190 780 200 94 29.6
A good measure of H 1475 182 850 220 93.5 27.4
comparison between motors is
I 1480 190 670 120 94 24
to divide the LRT% by the
LRC% - the bigger the
number, the better the result
Torque developed at 3 x FLC
Reduced Voltage Sample Of Typical 110kW Motors
Starting Amplifies Motor Speed FLC LRC LRT % FL Torque
(rpm) (amps) (%FLC) (%FLT) Efncy @3xFLC
Motor Differences
A 1470 191 600 263 93 65.8

Torque is reduced by the B 1475 184 600 190 93.5 47.5

square of the current C 1475 191 570 150 92 41.6
reduction.
Eg:- If you halve the current D 1480 187 660 190 94.5 39.2
the result will be motor E 1470 185 550 120 92 36
torque
F 1470 191 670 150 93 30.1
Motors B & G produce almost G 1480 190 780 200 94 29.6
the same torque at full
H 1475 182 850 220 93.5 27.4
voltage.
I 1480 190 670 120 94 24
Motor B produces 60% more
start torque at 3 x FLC.
 2
How To Calculate
Start Torque
Start Torque = LRT x ( StartLRC
Current
)
2
Follow the example and 65.8% = 263% x ( 300%
600%
)
calculate the start torque at
3 x FLC for motors B, C & D.

Motor LRC LRT TORQUE

(%FLC) (%FLT) @ 3 X FLC
A 600 263 65.8
B 600 190 47.5
C 570 150 41.5
D 660 190 39.3
Summary
Selecting a motor with low
Locked Rotor Current (LRC)
and high Locked Rotor Torque
(LRT) will:

- Reduce start current.

- Increase start torque.

- Reduce soft starter cost.

Full Voltage Starting
Current rises instantaneously
to LRC levels. This causes a 300 700
current transient that can have

FULL LOAD TORQUE (%)

250 600
undesirable effects on the
supply. 500

CURRENT (%)
200
400
Current gradually falls as 150
motor speed increases. 300
100
200
Motor loading affects only the
50
time taken for acceleration, 100

not the magnitude of current 0 0

which is always LRC. 100 90 80 70 60 50 40 30 20 10 0
SLIP (%)
Full Voltage Starting
Torque rises instantaneously
to LRT levels. This causes a 300 700
torque transient that can be

FULL LOAD TORQUE (%)

250 600
damaging.
500

CURRENT (%)
200
Typical torque falls from LRT 400
to Pull Out Torque before 150
rising to Breakdown Torque 300

just before full speed. 100

200

50 100

0 0
100 90 80 70 60 50 40 30 20 10 0
SLIP (%)
Full Voltage Starting
Limitations
300 700
1. Current transient
2600

FULL LOAD TORQUE (%)

250
2. Current magnitude
500

CURRENT (%)
3. Torque transient 200

4. Torque magnitude 400

150
300
100
Reduced voltage starting 200
attempts to overcome these 50 100
limitations by applying the
voltage gradually. 0
13 4 0
100 90 80 70 60 50 40 30 20 10 0
SLIP (%)
 Direct on Line
START

Line Contactor
Overload
% VOLTS
100
80
60 Run
Run
40 Start
Start
20
0
TIME
Reduced Voltage
Starters
Electromechanical
-- Primary Resistance
-Auto-transformer
- Star/Delta

Electronic
- Soft Start
Primary Resistance
RUN
Resistors are connected in CONTACTOR
series with each phase,
between the isolation
contactor and the motor.
The voltage drop across the
resistors results in a reduced
voltage applied to the motor,
thus reducing start current M
3~
and torque.

LINE START THERMAL MOTOR

CONTACTOR RESISTORS OVERLOAD
Primary Resistance
Set for 4 x FLC start current.
300 700

FULL LOAD TORQUE (%)

Limitations: 250 600

- Difficult to change 500

CURRENT (%)
resistance 200

- Dissipate a lot of heat 400

150
- Limited number of starts per 300
hour 100
200
- Start characteristics change
between starts if resistors 50 100
have not totally cooled
0 0
- Hard to start high inertia
100 90 80 70 60 50 40 30 20 10 0
loads
SLIP (%)
Primary Resistance
Set for 3.5 x FLC start current.
300 700

Start voltage is determined by

FULL LOAD TORQUE (%)

250 600
the resistors used. If the
resistance is too high there 500

CURRENT (%)
200
will be insufficient torque to 400
accelerate the motor to full 150
300
speed.
100
200
The reduced voltage start 50 100
time is controlled by a preset
timer. If the time is too short, 0 0
the motor will not have 100 90 80 70 60 50 40 30 20 10 0
achieved full speed before SLIP (%)
the resistors are bridged.
START
Run Contactor Primary
Resistance

Line Contactor Resistors

Overload

% VOLTS
100
80
60 Run
Run
40
Start
Start
20
0
TIME
Auto-transformers
The Auto-transformer Starter
employs an auto-transformer
to reduce the voltage during Run
(A) Start Contactor
Contactor
the start period. The
transformer has a range of
output voltage taps that can 3 Phase
Auto Transformer
be used to set the start Thermal
Overload
voltage. (B) Start Contactor

The motor current is reduced

M
by the start voltage reduction, 3~
and further reduced by the
transformer action resulting in
a line current less than the
actual motor current.
Auto-transformers
60% Tap
300 700

Limitations:

FULL LOAD TORQUE (%)

250 600
- Limited voltage taps
500

CURRENT (%)
- Limited number of starts per 200
hour 400
150
- Torque reduced at all
300
speeds 100
- Costly 200

50 100

0 0
100 90 80 70 60 50 40 30 20 10 0
SLIP (%)
Auto-transformers
50% Tap
300 700

The initial start voltage is set

FULL LOAD TORQUE (%)

250 600
by tap selection, and the start
500

CURRENT (%)
time is controlled by a timer. 200
If the start voltage is too low, 400
or the start time incorrectly 150
300
set, the transition to full
100
voltage will occur with the 200
motor at less than full speed, 50 100
resulting in a high current and
torque step. 0 0
100 90 80 70 60 50 40 30 20 10 0
SLIP (%)
START Star Point Auto-
Contactor
transformer

Transformer
Contactor

Line Contactor Overload

% VOLTS
100
80
60 Run
Run
40
Start
Start
20
0
TIME
Star/Delta
The motor is initially
connected in star
configuration and then,
after a preset time, the Main Delta
Contactor Contactor
motor is disconnected from
the supply and Thermal
Overload
reconnected in delta
configuration. The current Motor
and torque in the star 3~
configuration are one third
of the full voltage current
and torque when the motor
Star
is connected in delta. Contactor
Star/Delta
Insufficient torque to 300 700
accelerate this load in star

FULL LOAD TORQUE (%)

configuration. 250 600

500

CURRENT (%)
Limitations: 200
- No adjustment possible. 400
150
- Open transition switching
300
between star and delta 100
causes damaging current 200
and torque transients. 50 100

0 0
100 90 80 70 60 50 40 30 20 10 0
SLIP (%)
 Star -
START Star Point
Contactor

Delta
Delta
Contactor

Line Contactor Overloa

% VOLTS d
100
80
60 Run
Run
40
Start
Start
20
0
TIME
Open Transition Occurs when the starter goes through an open circuit
stage in the switching sequence. Stage [1] connection
Switching to the reduced voltage; [2] disconnect from the reduced
voltage (open circuit); [3] connect to the full voltage.

Open transition starting causes severe current & torque

transients that can be more detrimental to the supply
and the mechanical equipment than full voltage starting.

When the motor is spinning and then disconnected from

the supply, it acts as a generator. Output voltage can be
the same amplitude as the supply. At the time of reclose
there can still be significant voltage present at the motor
terminals.

Voltage generated by the motor at the instant of reclose

may be equal to the supply voltage but exactly out of
phase. This equates to reclosing with twice the supply
voltage on the motor. The result is a current of twice
locked rotor current and a torque transient of four times
locked rotor torque.
 Trigger circuit
Phase
PhaseAngle
AngleControl
Control

N
Reduced Voltage I 2
Starting T
ST
= LRT x ( LRC
ST
)
Reduces start current.
300 700
Reduces start torque by the

FULL LOAD TORQUE (%)

600
square of the current 250
reduction. 500

CURRENT (%)
200

Current can only be reduced 400

150
to the point where the torque 300
output from the motor exceeds 100
the torque required by the 200

load. 50 100

0 0
100 90 80 70 60 50 40 30 20 10 0
SLIP (%)
 Large Reduction
Reduced Voltage Small Reduction at 95% speed
Starting at 50% speed
300 700
To be effective, a reduced

FULL LOAD TORQUE (%)

voltage starter must allow the 250 600

motor to accelerate to around 500

CURRENT (%)
200
90% speed before applying full
voltage. 400
150
300
Below this speed the current 100
200
will step through to almost
LRC levels thus removing any 50
100
benefit from the reduced
0 0
voltage starter.
100 90 80 70 60 50 40 30 20 10 0
SLIP (%)
Soft Starter
Soft Starters control the
voltage applied to the motor
by the use of solid state AC
switches (SCRs) in series with
M
the supply to the motor. 3~

Contactor AC Switches Overload Motor

Soft Starter
- Minimum possible start
300 700
current
- No current steps

FULL LOAD TORQUE (%)

250 600
- No torque steps
500

CURRENT (%)
- Good start torque 200
characteristics 400
150
300
100
200

50 100

0 0
100 90 80 70 60 50 40 30 20 10 0
SLIP (%)
START
Soft Starting

% VOLTS
100
80
Run
Run
60
40 Start
Start
20
0
TIME
Summary
Motor characteristics set the
limits of what can be achieved
with a soft starter.

Pay special attention to motor

characteristics when:
- it is important to minimise
start current
- it is important to maximise
start torque
- dealing with large motors
(200kW +)
Summary
Soft start is technically the
best reduced voltage starting
system.

Star/Delta starting is the

cheapest and most commonly
employed reduced voltage
starting system. However its
performance characteristics
are damaging.
 Why Use Soft Starters

Because;

they reduce electrical and

mechanical stresses beyond the
capabilities of electro-mechanical
reduced voltage starters.

This further reduces machine

downtime, increasing plant
productivity.

Note however, that the level of performance is dependant

upon the design of the soft starter and functionality it
offers.