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    Unit4 Motor Cotrol Circuit

    Uploaded by

    Dagnachew

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    © All Rights Reserved
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    Motor Control Circuits In the early history of industrial development, machines in workshops and factories were run from a common line shaft. The line shaft was driven by a large motor which was connected by means of belts to the various individual motor drives. This type of industrial drive had many disadvantages. With the advent of time the demands on production increased and a varicty of require- ments for individual machines emerged. This necessitated individual control of machines, Thus the common line shaft was replaced by independent motors controlling individual machines. This enabled more flexible operation in machine shops. Different machines in the same machine shop may have widely different requirements like frequent starts and stops, periodic reversals, high starting torque, constant speed, variable speed etc. These and other individual requirements of a variety of machincs in a factory are met by selecting separate motors matching the needs of each machine. With individualisation of drives i machine shops, need was felt for automatic operation of driving motors. A motor is selected to match the load on the machine which itis to drive, the duty cycle and the type of operation. In today's industry machines are gencrally controlled automatically. To make automatic operation possible, machines are provided with a control sircuit. The control circuit design is determined by the operating requirements of the motor and the machine it is driving. In the later section of this chapter the basic components and principles of control are explained. it ha er pw control circuit compo- examples, it has been shown how contr ' I circuits of various requirements. Through practi Fents are used to make control ; . The word ‘control’ means governing oF regulating the functions of a hokor ot a machine, Control circuits perform function’ sar is bala ope ig, Chang. ing speed, protection, reversing, sequence operation 4 nas " ‘aducdton Before dealing with control circuits, @ brief ve reversing ste hid bea Motor with particular reference to method of starting Biven, ne Electrical Design: Estimating and Costing 9.1 INTRODUCTION TO AC MOTORS AC motors are of two main types, namely, induction oto synchro nous motors. Most of the industrial drives used thet’ De ae hee induction motors. Single phase indetion Farge asters, relrigerators, ai like wa chines, cc’ s, WE Se aprlicatons, ke a motes ned as indus des are OF Pe namely, squirrel cage motors and slip-ring motors: is the most widely used a.c. motor because of its simple construction, Low initial oe en Seah in operation and easy maintenance. For constant spe ser es Wh He ating duty is comparatively ight and infrequent, this tyPe of MOVES . Starting performance of a cage motor varies considerably wl its desi, A typical squirrel cage induction motor would have 130 percen starting Logue with 600 percent starting current when started dircct-on-line. High starting current causes heavy drop in the line voltage and adversely affects the operation of other motors connected on the line, For this reason it may be required to restrict the starting current of motors. The squirrel cage induction motor Situations where the starting current must be restricted, and high starting torques are not required, instead of direct-on-line starting, star-delta starting may be cmployed. In star-delta starting, the motor is started with the stator ‘winding star conneeted, When the motor comes up to near rated speed, the Stator winding is connected in delta by a switching mechanism. This has the effect of reducing the phase voltage to about 58% (1/3) of its normal value during starting, thus reducing both starting current and starting torque to approximately 1/3 of the direct-on-line value (as torque is proportional to square of the applicd voltage). An alternative to star-delta starting is the auto-transformer starting. This method of starting is often used for large motors. The motor is started reduced voltage available from auto-transformer tappings and switched on to full line voltage when running up at full speed. Auto-transformer starter is more expensive than the star-delta starter but has the advantage of greater Mlexibility as variable starting torqu be obtained by changing the au! ry le can b ransformer tappings. ein es of loads require a higher starting torque than is obtainable Squirrel cage motors. In addition, variation of speed over a large range ® a requirement in certain applicati u ications. cs irements, WON rotor induction motors, ‘soe ng ee ee eat ‘ called slip-ring inducti are used. Int slip-ring induction motor, th si ST sind taalae tn thet oe fing are taken out via slip-ri9s> i on alt, to be cone out: side, Addition of extra resic ener Ss fi resistance in the ea “ag hel develop high startin stance in the rotor circuit during starting Ml ig torque. By varying the cots! he speed of the motor and in equal steps t external resistance simulta can also be varied. But this meth? Motor Control Circuits figure 9.1. STARTING RESISTANCE 3 PHASE ABC INDUCTION MOTOR — KNIFE SWITCH Figure 9.1: Slip-ring induction motor connections. 92 STARTING OF 3-PHASE SQUIRREL CAGE INDUCTION MOTOR To refresh our knowledge it will be remembered that the r cage induction motor consists of conductors placed in slots conductors being short circuited on either side by means of end rings. The conductor cage thus formed on the rotor, makes the secondary winding while the stator winding acts as the primary. It is evident, therefore, that if the stator terminals of a squirrel cage indu motor, whose rotor is at rest, is Connected directly to the supply, without using any starting device, the motor is Placed in the same condition as a transformer with the secondary short Gircuited with the primary winding connected to the supply. Owing to the low resistance of the rotor conductors, the motor, unless it be of avery small size, will draw very high current causing a large voltage drop in the supply lines affecting adversely the operation of other machines connected n the same supply lines. Three-phase cage-type induction motors may be started by the following methods: (1) Direct-on-line starting. ‘otor of a squirrel on rotor core, the (2) Auto-transformer starting. (3) Star-delta starting. (8) Direct-on-Line (DOL) Staring . eat Direct-on-li farting, ic. switching on the motor directly across full Woe ihe, i Ine Dio economical method of starting. Direct-on-line Starting is sometimes referred to as “Full Voltage Starting.” Most modern Motors are designed not only to withstand full voltage starting, but are also je wBned with low starting current to enable them to be sees 08 distribution NS without producing objectionable voltage drops. Sce figure 9.2 tecrical Design: Estimating and Costing 318 RYB HASE STARTER sf INDUCTION — MOTOR ing, using magnetic contactor 9.2: Connection of a typical DOL start Figure 9.2: Connection of a typi ne using for a squirrel cage induct (b) Star-Deita (¥/D) Starting ‘This method of starting requires both the ends of each stator phase winding (ie. six leads in all) to be brought out, to enable, by external switching, connecting the winding in star at starting and in delta when the motor has run upto rated speed. The starting connection is-always star so that the voltage across each phase winding is 1//3 or 57.7% of that which appears across each stator phase when connected in delta. Thus reduced voltage is applied at starting, Figure 9.3 shows the connection diagram for star-delta method of starting a squirrel cage induction motor. In this figure the switch is manually operated. Automatic star-delta switching is obtained by the use of push- buttons, contactors, time delay relays, etc. and will be discussed later. In this method, obtaining reduced voltage at starting has the limitation that the starting voltage is fixed at 57.7% of the line voltage. Should it be necessary to have higher torque at starting, this method of starting is not applicable. Recourse is then taken to auto-transformer starting, (c)_ Auto-transformer Starting In auto-transformer starting, low voltage is applied across the motor termi nals by using a three-phase auto-transformer. The voltage to be applied can be chosen by selecting appropriate tappings in the auto-transformer. In the running position the motor is connected directly to the supply and the aul” transformer is cut out of the circuit. See figure 9.4, This type of starter is more expensive than the star-delta starter, but can used with any motor whether star or delta connected. The provision of sever taps on the transformer allows a range of adjustments to suit starting torque and current requirement. As in the star-delta case, the starting torque therefore the initial current taken from the supply is reduced. Howeres advantage of auto-transformer starting is that current reduction cal Motor Control Circuits STATOR WINDING MOTOR Figure 9.3: Typical connection diagram for star-delta starting of a ‘Sephase squirrel cage induction motor. AUTO- TRANSFORMER » STATOR WINDING Figure 9.4: Connection diagram of auto-transformer starting for a aquirrel cage induetion motor. ign: Estimating and Costing Electrical Desi" Estima " Electrical 0) yRREL CAGE MOTOR 93 STARTING MULTI SPEED sQu two separate stator windings or be of the Two specd motors ids, two separate star wings ning “ye speed of an induction motor single in herent numberof poles are 1 a (pe Sronber of poles for wh ie Cola to gine depends on the number C1 PE omnained bY reanouing the ce ee stator winding (0. STO les in the StF ag capable of bein different number of effective Poy agg gnother winding cap: cof b ime have one winding for one Peorespe 1 motors usually are won wt oi regrouped [oF Wie ich ean be regrouped 10 8 two sped. In thi tex on windings cach o} . Sonsidered. Change Over of connection from on. two specd motors are cons ally but now-a-days this is achieved by wvinding to the other can be done manwaly means of contactors and pushbuttons: 9.4 STARTING WOUND ROTOR MOTORS: The wound rotor motor is © entially similar to bere nee cage motor except that it has windings, similar to the ones on ihe stator, instead of Shore-circuited bars, on the rotor. High starting trae can be obtained by connecting extra resistance in scri¢s with the rotor circuit at starting. This extra resistance is gradually cut out of the circuit. Under running condition the spced of the motor can also be varicd by varying the rotor circuil resistance in steps. Three phase supply is given to the stator windings with full extra reustance on the rotor using contactors. The rotor resistance gets cul out in steps as the motor picks up speed. The variation of rotor resistance for starting ‘as well as speed control may be achieved by different ways. The rotor resistance control may be achieved by a manual drum controller, a motor driven drum controller, a liquid rheostat or a magnetic contactor appropriately designed. 9.5 STARTING OF SYNCHRONOUS MOTORS _ The synchronous motor has a winding, on the stator simitar to that of at induction motor. On its rotor, in addition to the d.c. field winding, sh circuited rotor bars are provided which enable it to start as an induction mote At starting supply is given to the stator through a reduced voltage starter. 5° figure 9.5. In the figure only one phase of the i The field winding at starting remai ort ! uto-transformer has ben SH esistance whil short circuited through a field dischars® nous speed | i rn neat voltage is applied to the stator. When g5ej synchee” voltage isa lied oe the discharge resistance gets disconnected and de Serle a ae tates ed Nitin while at the samme time full eI st ae ie ached ening. The opening and closing of circuits as explaie shown in figure 9.5, rough operation of start and run contactor com igure 9.5, the details of which will be explained later. otor Control Circuits 321 EXCITATION AUTO TRANSFORM SONTROL. BENERATOR FIELD STATOR DISCHARGE RESISTANCE] S: START R: RUN Figure 9.5: Starting of a synchronvus motor. 96 STOPPING OF MOTORS Motors may be stopped manually or automatically. Automatic stopping is accomplished by the use of limit switches, float switches etc. Manual stopping \s effected by push buttons or switches. Plugging is the most widely used method of quickly stopping an induction motor on ho load, The motor stator is switehed off and then momentarily ‘nergised in reverse direction. This type of stopping, however, is not suitable for motors which are holding loads like cranes or lifts. i ists, it lised that In the case of equipment such as cranes and hoists, it must be reali the load has a tendency to tura the motor. This is known as overhauling load. Induction motors used for this purpose are generally of the wound rotor type. Stopping is preceded by slowing down of the motor. This slowing helps to Aullify the overhauling effect. As soon as the motor is switched off from the ine, a mechanical break is automatically applied which locks the motor shaft “onnected to the load. 57 CONTACTOR CONTROL CIRCUIT COMPONENTS i i ing the direction of Bs i the starting, stopping, reversing tt i ta motors inl oni These arc achieved by designing suitable “ontrol circuits using contactors, relays, push buttons ete. Electrical Desig: Estimating and Cog, % Shown in figure 9.23, Exactly this is the point of intersection of both Sharacte ics. It should be kept in mind that take-over current in ng Should be less than six times the full load current, otherwise the fuse may blow Off for currents other than the short circuit currents. 1 ' 7 ' THERMAL OVER, . LOAD RELAY —*re—— FUSE Qs ' g t Z, ‘ s ‘ 8 TAKE OVER a> POINT ‘ a {© THERMAL OVERLOAD w? + \Retay 2, FUSE 123 6 567 6 § ON RD 1 CURRENT (IN TERMS OF RATED CURRENT) —» Figure 9.23: Time current characteristics for the coordination of thermal overload relay and fuse for overall protection of motors. 90 SCHEMATIC AND WIRING DIAGRAMS FOR MOTOR CONTROL CIRCUITS As mentioned in section 1.5 two types of diagrams namely schematic dia- gram and wiring diagram are drawn for any electrical circuit. Accordingly for various motor control circuits, both these types of diagrams will be drawn. In this section, different contactor control circuits used for control of motors are cussed. For the convenience of the students, design of a number of control circuit problems have been provided along with their explanation, The problems have also been graded i.e. simpler problems have been discussed first. 9.10.1 Direct-on-Line (DOL) Starting of a Three-phase Induction Motor Three phase induction motors can be started direct-on-line i.e. by supplying the rated three-phase voltage to the motor terminals at the time of starting This can be done simply by using a triple pole switch, To incorporate m4 protection against overloads a thermal overload relay and a contactor wait a be used instead of a triple pole switch, The contactor can be encrgise ie de-energised by pressing separate push buttons for starting or nen tor, The wiring diagram for the push-button control direct-on-line I ait mMOtOT phase induction motor is shown in figure 9.24 (b). The sche Sal for the control circuit has been shown in figure 9.24 (a) motor Control Circuits 0 pte petlS/240.V mzo~<. OFF 81 oN ‘ B2 81 “ (d) Figure 9.24: Direct-oncline starting ofa three phase induction motor, (2) Schematic diagram for the control circuit (b) Complete wiring diagram When the control circuit is energised by pressing the push button B,, th motor gets 3-phase supply through the contacts of the electromagnetis contactor which are normally open. The motor is protected against overload by athermal overload relay which open circuits the control circuit when overloac occurs. Cartridge fuses are provided on the power circuit for the protection of the motor. Moreover, in case of short circuit as the thermal overload relay is toc 1 slow, the contactor will not have sufficient capacity of breaking short circuit current. A hold-on contact for the start push buttor B is provided through a NO contact of the contactor as the push-button makes a momentary contact only. When it is desired to stop the motor, the OFF push-button B, is pressed which de-energises the control circuit. Thus, the main contacts through which the motor was getting supply and also the auxiliary contact (hold-on contact) get opened. The motor can be re-started again by pressing the push-button B; cer supply, the contactor becomes de-energised In the event of failure of pows r : and the motor stops automatically and will not start running when the power Supply is restored. 9.10.2 A Motor Fed from either of Two Supply Sources In figure 9.25 (a) is shown a three-phase induction motor having facility of testing supply ‘oh Sitner of two supply sources through (wo different 340 Electrical Design: Estimating and Costing contactors. Normally the motor will get supply through the contactor Atom supply source I. In case of failure of power supply soul them canbe got connected to source It through the energisation CN istobe ensured while designing the control circuit that when actos Betting supply for one source, it should not be possible for it.to get Supply trom the other source. . | The diagram of the control circuit to mect the above requirements is shown in figure 9.25 (b). SUPPLY SOURCE 1 SUPPLY SOURCE I 5 § R a “O00 a (a) ty) Figure 9.25: A three-phase induction motor having the facility of getting power from any one of two sources. When push button B, is pressed contactor coil A gets energised. The motor gets three-phase supply and starts rotating. The contactor coil A remains cnergised even when the pressure on push-button B, is withdrawn as now the contact a, of the contactor A is closed. In the event of failure of power supply of source I, the motor can be connected to source II by pressing push-button B,. Contact b, is the hold-on contact of contactor B which ensures that contactor coil B remains energised even when the pressure on the push-button B, is released. The NC contact of the push button B, has been connected in series with the contactor coil B for providing mechanical interlocking of the contactor, That is when push button contact B, which is connected in series with coil A is closed, its other contact B, which is connected in series with coll B opens. Similarly one NC contact of push-button B, has been connected if series with the coil A. Thus it is not possible to energise both the contactors A and B simullancously. To ensure double protection against the motor getting ncously from the two sources one NC contact of contactor Ais: with the contactor coil B and vic Sa. supply simulta i has been connected in se Motor Control Circuits ua Push button B, is meant for switching off the motor at any time. Thermal overload relay contacts €, and e, and the cartridge fuse have all been connected in series. In figure 9.25 the power circuit and the schematic representation of the control circuit have been shown separately, (The student may draw the complete wiring diagram.) 9.103 Direct Reversing of a Three-phase Induction Motor The direction of rotation of a three-phase induction motor is reversed if the supply connections of any of the two phases are reversed. In the power circuit diagram shown in figure 9.26(a) three-phase induction motor is shown having possibility of getting supply through energisation of cither contactor A or contactor B. The motor will rotate in the reverse direction when it receives supply through contactor B. z0

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