Solid State Motor control inside-the-delta

How to wire correctly an SMC-3 or an SMC-Flex in delta mode?

Using a softstarter in the inside-the-delta wiring is a method that finds increasing

acceptance in many motor control applications. This technique consists in placing the
switching devices (thyristors) in series with each motor winding while the motor is
wired in delta. As in delta, the winding currents are 3 time smaller than the motor
phase currents in the incoming lines, this allows for more compact softstarter
designs.
Another good reason of using this wiring technique is for revamping existing star-
delta starter applications. In these cases, the existing motor cables (6 wires) can be
re-used and replacing the starter with an electronic softstarter becomes a very
efficient and easy way of upgrading an installation.
However, the fact that 6 wires to the motor are necessary can sometimes negatively
impact the overall cost of the application. This is particularly the case when the
distance between starter and motor is significant.

Softstarter in the inside the delta connection

When using a softstarter in the inside the

delta configuration, there is no transition
between star and delta. The motor is in delta
before starting. The controller limits the
voltage by switching the thyristors sequentially
in all of the three phases during the starting
time. In order to get a smooth start, it is of
upmost importance that the wiring is done
correctly. The manufacturer’s instructions
must be followed.
Consequently, with Allen-Bradley softstarters
the motor phases must be wired sequencially
according to the Fig.1.
A different sequence in wiring the motor
phases to the softstarter could cause the
softstart to be ineffective (behaviour
approaching a DOL start) or in some cases
U1 W1 not to start at all.

U2
W2

V2 V1

Fig. 1: Wiring diagram of SMC-3 in the Delta mode

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Correct and incorrect wiring schematics

Let’s have a look at 2 different wiring possibilities when using the SMC inside
the delta:

L1 L2 L3

U1 V1 W1

U2 V2 W2

Wiring A: correct Wiring B: incorrect

While both wiring types A and B will work and result in the motor rotating in
the same direction when controlled with contactors, wiring B cannot be used
when the start is controlled by solid state devices like thyristors.
During the starting phase, an electronic control unit fires the thyristors
sequentially in a way that the resultant voltage to the motor is reduced and
increases over the time. In order to have the correct torque produced at the
right moment, the phase sequence must comply to the internal algorithm of
the softstarter. For this reason, the wiring type A is required.
Using the SMC-3 with the wiring type B will result in a starting behaviour that
will not be optimal, being closer to a DOL start and thus not bring the
expected smoothness and current limiting effect.
Using an SMC-Flex with the wiring type B will not allow starting the motor at
all, due to an internal prestart test that will not succeed. The start sequence
will be aborted.
With increasing distance between softstarter and motor, the risk of using the
wrong wiring increases because the electrician doesn’t have a simultaneous
access to both ends of the cable. Special care is required to make sure the
cable is wired the correct way.
Many mistakes and costly trouble-shooting actions have resulted from using
the incorrect wiring in inside-the-delta applications.

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Practical wiring considerations

Correct SMC-3 inside the delta wiring to the motor terminal box

Motor terminal box

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Correct inside-the-delta wiring of the SMC-Flex or the SMC-3 (108 … 480A) to
the motor terminal box

T5
T4
T6
T3
T2
T1

Connect:
T1 to U1
T2 to V1
T3 to W1
T6 to W2
T4 to U2
T5 to V2

Motor terminal box

Litterature:
[1] Application guide SMC Controllers, Rockwell Automation publication 150-
AT001B-EN-P
[2] User manual SMC-Flex, Rockwell Automation publication 150-UM008G-EN-P

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