Variable-frequency drive

From Wikipedia, the free encyclopedia

Small variable frequency drive

Hitachi J100 VFD

A variable-frequency drive (VFD) is a system for controlling the rotational speed of an alternating current (AC) electric motor by controlling the frequency of the electrical power supplied to the motor.[1][2][3] A variable frequency drive is a specific type of adjustable-speed drive. Variablefrequency drives are also known as adjustable-frequency drives (AFD), variable-speed drives (VSD), AC drives, microdrives or inverter drives. Since the voltage is varied along with frequency, these are sometimes also called VVVF (variable voltage variable frequency) drives. Variable-frequency drives are widely used in ventilation systems for large buildings; variable-frequency motors on fans save energy by allowing the volume of air moved to match the system demand. They are also used on pumps, elevator, conveyor and machine tool drives.

Contents

1 Benefits of VFD Systems o 1.1 Energy Savings for VFD Systems o 1.2 Extended Equipment Life and Reduced Maintenance 2 VFD types 3 VFD system description o 3.1 VFD motor o 3.2 VFD controller o 3.3 VFD operator interface 4 VFD operation 5 Power line harmonics 6 Application considerations o 6.1 Transmission line effects o 6.2 Motor bearings 7 Available VFD power ratings 8 Dynamic braking 9 Regenerative variable-frequency drives 10 Brushless DC motor drives 11 See also 12 References 13 External links

Benefits of VFD Systems

Energy Savings for VFD Systems

AC motor-driven applications that do not require full speed can save energy by controlling the motor with a variable speed drive. Energy cost saving with variable torque can be significant, often paying for the cost of VFD within a matter of months. In variable torque applications such as fans and blowers, the torque required varies roughly with the square of the speed, and the horsepower required varies roughly with the cube of the speed, resulting in a large reduction of horsepower for even a small reduction in speed. The motor will consume only 25% as much power at 63% speed than it will at 100% speed. This is referred to as the Affinity Laws, which define the relationships between speed, flow, torque, and horsepower.

Extended Equipment Life and Reduced Maintenance

Single-speed starting methods start motors abruptly, subjecting the motor to a high starting torque and to current surges that are up to 10 times the fullload current. Variable speed drives, on the other hand, gradually ramp the motor up to operating speed to lessen mechanical and electrical stress, reducing maintenance and repair costs, and extending the life of the motor and the driven equipment. Soft starts, or reduced-voltage soft starters (RVSS), are also able to step a motor up gradually, but drives can be programmed to ramp up the motor much more gradually and smoothly, and can operate the motor at less than full speed to decrease wear and tear. Variable speed drives can also run a motor in specialized patterns to further minimize mechanical and electrical stress. For example, an S-curve pattern can be applied to a conveyor application for smoother decel/accel control, which reduces the backlash that can occur when a conveyor is accelerating or decelerating....

VFD types
All VFDs use their output devices (IGBTs, transistors, thyristors) only as switches, turning them only on or off. Using a linear device such as a transistor in its linear mode is impractical for a VFD drive, since the power dissipated in the drive devices would be about as much as the power delivered to the load. Drives can be classified as:

Constant voltage Constant current Cyclo converter

In a constant voltage converter, the intermediate DC link voltage remains approximately constant during each output cycle. In constant current drives, a large inductor is placed between the input rectifier and the output bridge,

so the current delivered is nearly constant. A cyclo converter has no input rectifier or DC link and instead connects each output terminal to the appropriate input phase. The most common type of packaged VF drive is the constant-voltage type, using pulse width modulation to control both the frequency and effective voltage applied to the motor load.

VFD system description

VFD system A variable frequency drive system generally consists of an AC motor, a controller and an operator interface.[5][6]

VFD motor
The motor used in a VFD system is usually a three-phase induction motor. Some types of single-phase motors can be used, but three-phase motors are usually preferred. Various types of synchronous motors offer advantages in some situations, but induction motors are suitable for most purposes and are generally the most economical choice. Motors that are designed for fixedspeed operation are often used. Certain enhancements to the standard motor designs offer higher reliability and better VFD performance, such as MG-31 rated motors.[7]

VFD controller
Variable frequency drive controllers are solid state electronic power conversion devices. The usual design first converts AC input power to DC intermediate power using a rectifier or converter bridge. The rectifier is usually a three-phase, full-wave-diode bridge. The DC intermediate power is then converted to quasi-sinusoidal AC power using an inverter switching

circuit. The inverter circuit is probably the most important section of the VFD, changing DC energy into three channels of AC energy that can be used by an AC motor. These units provide improved power factor, less harmonic distortion, and low sensitivity to the incoming phase sequencing than older phase controlled converter VFD's. Since incoming power is converted to DC, many units will accept single-phase as well as three-phase input power (acting as a phase converter as well as a speed controller); however the unit must be derated when using single phase input as only part of the rectifier bridge is carrying the connected load.[8] As new types of semiconductor switches have been introduced, these have promptly been applied to inverter circuits at all voltage and current ratings for which suitable devices are available. Introduced in the 1980s, the insulated-gate bipolar transistor (IGBT) became the device used in most VFD inverter circuits in the first decade of the 21st century.[9][10][11] AC motor characteristics require the applied voltage to be proportionally adjusted whenever the frequency is changed in order to deliver the rated torque. For example, if a motor is designed to operate at 460 volts at 60 Hz, the applied voltage must be reduced to 230 volts when the frequency is reduced to 30 Hz. Thus the ratio of volts per hertz must be regulated to a constant value (460/60 = 7.67 V/Hz in this case). For optimum performance, some further voltage adjustment may be necessary especially at low speeds, but constant volts per hertz is the general rule. This ratio can be changed in order to change the torque delivered by the motor.[12] In addition to this simple volts per hertz control more advanced control methods such as vector control and direct torque control (DTC) exist. These methods adjust the motor voltage in such a way that the magnetic flux and mechanical torque of the motor can be precisely controlled. The usual method used to achieve variable motor voltage is pulse-width modulation (PWM). With PWM voltage control, the inverter switches are used to construct a quasi-sinusoidal output waveform by a series of narrow voltage pulses with pseudosinusoidal varying pulse durations.[9][13] Operation of the motors above rated name plate speed (base speed) is possible, but is limited to conditions that do not require more power than the nameplate rating of the motor. This is sometimes called "field weakening" and, for AC motors, means operating at less than rated volts/hertz and above rated name plate speed. Permanent magnet synchronous motors have quite limited field weakening speed range due to the constant magnet flux linkage. Wound rotor synchronous motors and induction motors have much wider speed range. For example, a 100 hp, 460 V, 60 Hz, 1775 RPM (4 pole) induction motor supplied with 460 V, 75 Hz (6.134 V/Hz), would be limited to 60/75 = 80% torque at 125% speed (2218.75 RPM) = 100% power.[14] At

higher speeds the induction motor torque has to be limited further due to the lowering of the breakaway torque of the motor. Thus rated power can be typically produced only up to 130...150% of the rated name plate speed. Wound rotor synchronous motors can be run at even higher speeds. In rolling mill drives often 200...300% of the base speed is used. Naturally the mechanical strength of the rotor and the lifetime of the bearings also limit the maximum speed of the motor. Consulting the motor manufacturer is recommended if more than 150% speed is required by the application.

PWM VFD Output Voltage Waveform An embedded microprocessor governs the overall operation of the VFD controller. The main microprocessor programming is in firmware that is inaccessible to the VFD user. However, some degree of configuration programming and parameter adjustment is usually provided so that the user can customize the VFD controller to suit specific motor and driven equipment requirements.[9]

VFD operator interface

The operator interface provides a means for an operator to start and stop the motor and adjust the operating speed. Additional operator control functions might include reversing, and switching between manual speed adjustment and automatic control from an external process control signal. The operator interface often includes an alphanumeric display and/or indication lights and meters to provide information about the operation of the drive. An operator interface keypad and display unit is often provided on the front of the VFD controller as shown in the photograph above. The keypad display can often be cable-connected and mounted a short distance from the VFD controller. Most are also provided with input and output (I/O) terminals for connecting pushbuttons, switches and other operator interface devices or control signals. A serial communications port is also often available to allow the VFD to be configured, adjusted, monitored and controlled using a computer.[9][15]
[16]

VFD operation
When an induction motor is first connected to a full voltage supply, it draws several times (up to about 6 times) its rated current. As the load accelerates, the available torque usually drops a little and then rises to a peak while the current remains very high until the motor approaches full speed. By contrast, when a VFD starts a motor, it initially applies a low frequency and voltage to the motor. The starting frequency is typically 2 Hz or less. Thus starting at such a low frequency avoids the high inrush current that occurs when a motor is started by simply applying the utility (mains) voltage by turning on a switch. After the start of the VFD, the applied frequency and voltage are increased at a controlled rate or ramped up to accelerate the load without drawing excessive current. This starting method typically allows a motor to develop 150% of its rated torque while the VFD is drawing less than 50% of its rated current from the mains in the low speed range. A VFD can be adjusted to produce a steady 150% starting torque from standstill right up to full speed.[17] Note, however, that cooling of the motor is usually not good in the low speed range. Thus running at low speeds even with rated torque for long periods is not possible due to overheating of the motor. If continuous operation with high torque is required in low speeds an external fan is usually needed. The manufacturer of the motor and/or the VFD should specify the cooling requirements for this mode of operation. In principle, the current on the motor side is in direct proportion to the torque that is generated and the voltage on the motor is in direct proportion of the actual speed, while on the network side, the voltage is constant, thus the current on line side is in direct proportion of the power drawn by the motor, that is U.I or C.N where C is torque and N the speed of the motor (we shall consider losses as well, neglected in this explanation). 1. n stands for network (grid) and m for motor 2. C stands for torque [Nm], U for voltage [V], I for current [A], and N for speed [rad/s] We neglect losses for the moment:

Un.In = Um.Im (same power drawn from network and from motor) Um.Im = Cm.Nm (motor mechanical power = motor electrical power) Given Un is a constant (network voltage) we conclude: In = Cm.Nm/Un That is "line current (network) is in direct proportion of motor power".

With a VFD, the stopping sequence is just the opposite as the starting sequence. The frequency and voltage applied to the motor are ramped down at a controlled rate. When the frequency approaches zero, the motor is shut

off. A small amount of braking torque is available to help decelerate the load a little faster than it would stop if the motor were simply switched off and allowed to coast. Additional braking torque can be obtained by adding a braking circuit (resistor controlled by a transistor) to dissipate the braking energy. With 4-quadrants rectifiers (active-front-end), the VFD is able to brake the load by applying a reverse torque and reverting the energy to the network.

Power line harmonics

While PWM allows for nearly sinusoidal currents to be applied to a motor load, the diode rectifier of the VFD takes roughly square-wave current pulses out of the AC grid, creating harmonic distortion of the power line input, especially in the current waveform. When the VFD load size is small and the available utility power is large, the effects of VFD systems slicing small chunks out of the AC grid generally go unnoticed. Furthermore, in low voltage networks the harmonics caused by single phase equipment such as computers and TVs are such that they are partially cancelled by three-phase diode bridge harmonics. However, when either a large number of low-current VFDs, or just a few very large-load VFDs are used, they can have a cumulative negative impact on the AC power waveform available to other utility customers in the same grid. When the utility voltage becomes misshapen and distorted, the losses in other loads such as normal AC motors are increased. This may in the worst case lead to overheating and shorter operating life. Also substation transformers and compensation capacitors are affected, the latter especially if resonances are aroused by the harmonics. In order to limit the voltage distortion, the owner of the VFDs may be required to install filtering equipment to smooth out the irregular waveform. Alternatively, the utility may choose to install filtering equipment of its own at substations affected by the large amount of VFD equipment being used. In

high power installations decrease of the harmonics can be obtained by supplying the VFDs from transformers that have different phase shift.[18] Furthermore, it is possible, instead of the diode rectifier, to use a transistor circuit similar to that which controls the motor. This kind of rectifier is called an active infeed converter in IEC standards. However, manufacturers call it by several names such as active rectifier, ISU (IGBT Supply Unit), AFE (Active Front End) or four quadrant rectifier. With PWM control of the transistors and filter inductors in the supply lines, the AC current can be made nearly sinusoidal. Even better attenuation of the harmonics can be obtained by using an LCL (inductor-capacitor-inductor) filter instead of single three-phase filter inductor. An additional advantage of the active infeed converter over the diode bridge is its ability to feed back the energy from the DC side to the AC grid. Thus no braking resistor is needed and the efficiency of the drive is improved if the drive is frequently required to brake the motor.

Application considerations
Transmission line effects
The output voltage of a PWM VFD consists of a train of pulses switched at what is called the carrier frequency. Because of the rapid rise time of these pulses, transmission line effects of the cable between the drive and motor must be considered. Since the transmission-line impedance of the cable and motor are different, pulses tend to reflect back from the motor terminals into the cable. The resulting voltages can produce up to twice the rated line voltage for long cable runs, putting high stress on the cable and motor winding and eventual insulation failure. Increasing the cable or motor size/type for long runs and using 480V or 600V motors instead of 230V will help offset the stresses imposed upon the equipment due to the VFD. (Modern 230v single phase motors are not affected). At 460 V, the maximum recommended cable distances between VFDs and motors can vary by a factor of 2.5:1. The longer cable distances are allowed at the lower Carrier Switching Frequencies (CSF) of 2.5 kHz. The lower CSF can produce audible noise at the motors. For applications requiring long motor cables VSD manufacturers usually offer dv/dt filters that decrease the steepness of the

pulses. For very long cables or old motors with insufficient winding insulation, more efficient sinusoidal filters are recommended. Expect the older motor's life to shorten. Purchase VFD rated motors for the application.

Motor bearings
Main article: Shaft voltage Further, the rapid rise time of the pulses may cause trouble with the motor bearings. The stray capacitance of the windings provides paths for high frequency currents that pass through the motor shaft and bearings. If the voltage between the shaft and the shield of the motor exceeds a few volts the stored charge is discharged as a small spark. Repeated sparking causes erosion in the bearing surface that can be seen as a fluting pattern. In order to prevent sparking the motor cable should provide a low impedance return path from the motor frame back to the inverter. Thus it is essential to use a cable designed to be used with VSDs.[19] In big motors a slip ring and brush can be used to provide a bypass path for the bearing currents. Alternatively, isolated bearings can be used. The 2.5 kHz and 5 kHz CSFs cause fewer motor bearing problems than the 20 kHz CSFs.[20] Shorter cables are recommended at the higher CSF of 20 kHz. (The minimum CSF for synchronize tracking of multiple conveyors is 8 kHz.) The high frequency current ripple in the motor cables may also cause interference with other cabling in the building. This is another reason to use a motor cable designed for VSDs that has a symmetrical three-phase structure and good shielding. Furthermore, it is highly recommended to route the motor cables as far away from signal cables as possible.[21]

Available VFD power ratings

Variable frequency drives are available with voltage and current ratings to match the majority of 3-phase motors that are manufactured for operation from utility (mains) power. VFD controllers designed to operate at 110 V to 690 V are often classified as low voltage units. Low voltage units are typically designed for use with motors rated to deliver 0.2 kW or 0.25 horsepower (hp) up to several megawatts. For example, the largest ABB ACS800 single drives are rated for 5.6 MW.[22] Medium voltage VFD controllers are designed to operate at 2,400/4,162 V (60 Hz), 3 kV (50 Hz) or up to 10 kV. In some applications a step up transformer is placed between a low voltage drive and a medium voltage load. Medium voltage units are typically designed for use with motors rated to deliver 375 kW or 500 hp and above. Medium voltage

drives rated above 7 kV and 5,000/10,000 hp should probably be considered to be one-of-a-kind (one-off) designs.[23] Medium voltage drives are generally rated amongst the following voltages : 2.3 kV, 3.3 kV, 4 kV, 6 kV, and 11 kV. The in-between voltages are generally possible as well. The power of M.V. drives is generally in the range of 0.3 to 100 MW; this involves a range of several different types of drives using different technologies.

Dynamic braking
Using the motor as a generator to absorb energy from the system is called dynamic braking. Dynamic braking stops the system more quickly than coasting. Since dynamic braking requires that the rotor be moving, it becomes less effective at low speed and cannot be used to hold a load at a stopped position. During normal braking of an electric motor, the electrical energy produced by the motor is dissipated as heat inside of the rotor, which increases the likelihood of damage and eventual failure. Therefore, some systems transfer this energy to an outside bank of resistors. Cooling fans may be used to protect the resistors from damage. Modern systems have thermal monitoring, so if the temperature of the bank becomes excessive, it will be switched off.[24]

Regenerative variable-frequency drives

Regenerative AC drives have the capacity to recover the braking energy of a load moving faster than the designated motor speed (an overhauling load) and return it to the power system.

Line regenerative variable frequency drives, showing capacitors (top cylinders) and inductors attached, which filter the regenerated power. Cycloconverters and current-source inverters inherently allow return of energy from the load to the line, while voltage-source inverters require an additional converter to return energy to the supply.[25] Regeneration is only useful in variable-frequency drives where the value of the recovered energy is large compared to the extra cost of a regenerative system,[25] and if the system requires frequent braking and starting. An example would be conveyor belt drives for manufacturing, which stop every few minutes. While stopped, parts are assembled correctly; once that is done, the belt moves on. Another example is a crane, where the hoist motor stops and reverses frequently, and braking is required to slow the load during lowering. Regenerative variable-frequency drives are widely used where speed control of overhauling loads is required.
[2][3][26]

Brushless DC motor drives

Much of the same logic contained in large, powerful VFDs is also embedded in small brushless DC motors such as those commonly used in computer fans. In this case, the chopper usually converts a low DC voltage (such as 12 volts) to the three-phase current used to drive the electromagnets that turn the permanent magnet rotor.

SOFT STARTER
Soft start is a term describing any electrical circuit which reduces excess current during initial power-up of an electric motor.

Contents
1 Introduction 2 What is a soft starter? 3 Why use a soft starter? 4 Construction 5 Control o 5.1 Open-Loop o 5.2 ClosedLoop 6 Applications/Topologies 7 Need for soft start 8 Soft starting methods 9 Logic Controller Application 10 References

11 See also

Introduction
In industrial applications, electric motors are used extensively and represent a significant percentage of total industrial electrical load . There are generally three different ways to start a motor: full-voltage, reduced voltage, and inverter. A full voltage, across-the-line, or direct on-line (DOL) start uses a contactor, which is a heavier duty three-phase relay. Reduced voltage starting can be accomplished via several different ways: auto-transformer, wye-delta, primary resistor/reactor, or with a solid state soft starter. Inverters are generally referred to as drives. This paper focuses on solid state soft starters (referred to as soft starter only from here on): what they are, why they are used, their construction, and applications.

What is a soft starter?

A soft starter is a solid state motor starter that is used to start or stop a motor by notching the voltage waveform, thereby, reducing the voltage to each phase of a motor and gradually increasing the voltage until the motor gets up to full voltage/speed all at a fixed frequency. The profile of the increase of voltage depends on the application. The voltage is reduced and controlled by 3 pairs of back-to-back silicon-controlled rectifiers (SCRs), which are a type of high speed thyristor. A soft starter takes the place of a contactor and can also take the place of an overload relay in a standard motor starting application.

Why use a soft starter?

In general, there are two reasons to use a soft starter: the power distribution network may not be able to handle the inrush current of the motor and/or the load cannot handle the high starting torque. As a rule of thumb, a motor utilizes around 600-800% of its full load current (FLA) to start. This current is referred to as inrush current or locked-rotor current. If a large motor is on a smaller power distribution network or on a generator system, this inrush current can cause the system voltage to dip, or to brown out. Brown outs can cause problems with whatever else is connected to the system, such as computers, lights, motors, and other loads. Another problem is that the system may not even be able to start the motor because it cannot source or supply enough current. Most industrial businesses run during the day can be fined or charged extra (Peak Demand charges) during this peak usage time for large transients caused by large horsepower (HP)/Kilowatt (kW) motor start ups. These Peak Demand charges can add up very quickly, especially if the motor needs to be started multiple times during any given day. The inrush current can be controlled one of two ways with a soft starter: either with a current limit (discussed later) or reduced linearly with the reduced voltage, and follows this approximation:

Applications such as conveyors may not be able to handle a sudden jolt of torque from an across-the-line start. Utilizing soft starters reduces the wear and tear on belts, conveyors, gears, chains, and gearboxes by reducing the torque from the motor. The torque decreases as a square of the reduced voltage, and follows this approximation:

Since soft starters are generally controlled and monitored by a microprocessor, a soft starter can add many features and protections fairly easily. It can offer a choice of the starting time, limited speed control, and energy savings. Power monitoring, such as three-phase current, three-phase voltage, power, power usage, power factor, and motor thermal capacity usage, can be implemented with current transformers, a voltage meter, and an internal clock. With the above implementations, protection, for the motor or the soft starter, from the items listed below (Table 1) can also be offered by stopping the firing of the SCRs, dropping out the bypass contactor (a contactor that carries the motor load after the motor is up-to-speed), and/or alerting a user via some form of communications with the microprocessor and another computer.

Construction
Generally, a soft starter is constructed with three pairs of SCRs reverse parallel connected to allow the current to flow to or from the motor. Soft starters can be made by controlling just one or two phases, but this page will focus on the most prevalent implementation, three-phase control. Each phase of a soft starter can be controlled with an SCR pair reverse parallel connected, an SCR/diode pair reverse parallel connected, or a triac, depending on cost and/or quality. The most prevalent switch in industry is probably the SCR pair and will also be the focus of this paper. Soft starters are used almost exclusively for starting and stopping and not during the run time because of the heat loss through the SCRs from the voltage drop across them. A standard assembly of a soft starter uses one SCR pair per phase and once the voltage gets to within approximately 1.1V of full voltage (depending on the voltage drop across the SCR) a bypass contactor (internal or external to the soft starter), running parallel to the SCR pairs, pulls in. Once pulled in the SCRs stop firing. Typically, the bypass contactor is much smaller than compared to what is needed for a full voltage start as the contacts only need to be able to handle the full load current of the motor. Since the mechanical contacts cannot handle the inrush current, the SCRs must be sized correctly to handle the motors locked-rotor current. The transition from SCRs to bypass should also be near full speed to minimize the jump in current.

Control
A soft starter reduces the voltage by notching the applied sinusoidal waveform. A notch is a non-technical term for the zero voltage area in the

middle waveform. As the notch decreases in size, the Vrms increases along with Irms. An initial voltage, determined by the user, is ramped up to full voltage by varying the firing angle depending on the preset profile of the soft starter. Soft starters can be controlled via open-loop or closed-loop control. All control schemes listed monitor back EMF of the motor as to not become unstable.

Open-Loop
An example of open loop control is the voltage ramp; the voltage ramps from an initial voltage to full voltage in a linear fashion without regards to the load. Pump start is another form of open-loop control. The pump starters firing circuit ramps up the voltage with a profile that allows the speed/torque to ramp in a more efficient manner and helps protect against water hammering, a common problem in pump applications.

Closed-Loop
Applications such as current limit use feedback from the motor or the line current/voltage to change the firing angle of the SCRs as necessary, hence closed-loop.

Applications/Topologies
Soft starters can be made for a reversing application by adding two extra SCR pairs that switch two phases. For example, line phase b is connected to load phase c and vice versa. L2 (b) is connected to T3 (c) and L3 (c) is connected to T2 (b) in Fig. 17. A delta configuration motor can also be controlled with a soft starter, but it will see more current than a line connected motor. As a way to get around the larger current switching, a soft starter can be wired inside the delta. Wiring in this configuration will allow the soft starter to control a larger motor than even line connected by a 3 advantage. For instance, an inside the delta soft starter can switch a 277A load versus a line connected soft starter needs to be able to switch 480A to control the same rated motor load. A disadvantage of inside the delta is that it requires six leads coming from the motor which can be an added expense with larger HP motors. In contrast, kick starting and low speed ramps are some other applications that can be implemented via different programming of SCR firing angles.

Need for soft start

Many electronic devices will consume a large initial current when first turned on (i.e. Inrush current) that can cause voltage fluctuations and affect the performance of other circuits connected to a common power supply. The source for this problem is often large capacitors with very low Input impedance. To counteract this issue, components can be added in series to throttle back the current initially as the device comes online. Soft starters are also used to start some types of lamps. A tungsten filament has a positive temperature coefficient of resistance: a cold filament has a smaller resistance by a factor of 8-10 than a hot filament, and allows a large inrush of current. This inrush coupled with uneven filament wear causes local temperature overshoot in hotspots during startup, further evaporating the thinner filament sections. While soft start has little effect on GLS lamp life, it can make a sizeable difference to a halogen lamp's life. High initial current can cause damage to other components such as semiconductors if they are not rated for the initial high current of loads such as filament lamps, motors or capacitors. Soft starts are sometimes used on larger equipment as well, such as electric motors in various applications. The current drawn by an electric motor during a start can be 2 to 10 times the normal operating current, and this can exceed the supply's ratings if not controlled. Finally soft start is widely used on hand held tools to prevent the tool being jerked out of position when switched on. Jumping of electric drills was a widespread issue in the 1970s when soft start was usually not fitted.

Soft starting methods

There are various ways to implement soft starting. The most popular for appliances is triac control which ramps up duty cycle over several cycles. A method used with some motors is to start with windings in series, switching them to parallel when partial speed has been reached. This is commonly known as Y- start. Increasing supply impedance has a semi soft start effect on motors, with initial current still being above run current, but by a much reduced amount. This method is not widely used. Current limiting and voltage ramp-up in electronic supplies are common methods of soft starting low voltage loads.

Logic Controller Application

This soft start is provided by a dedicated output of a programmable logic controller. They can be used to start motors where Variable-frequency drive (VFD) are not used. This allows a cheaper starting option for motors that will run at a constant speed.[1]

Motor soft starter

From Wikipedia, the free encyclopedia

Examples of motor soft starters

[1]

A motor soft starter is a device used with AC electric motors to temporarily reduce the load and torque in the power train of the motor during startup. This reduces the mechanical stress on the motor and shaft, as well as the electro dynamic stresses on the attached power cables and electrical distribution network, extending the lifespan of the system.[2] Motor soft starters can consist of mechanical or electrical devices, or a combination of both. Mechanical soft starters include clutches and several types of couplings using a fluid, magnetic forces, or steel shot to transmit torque, similar to other forms of torque limiter. Electrical soft starters can be any control system that reduces the torque by temporarily reducing the voltage or current input, or a device that temporarily alters how the motor is connected in the electric circuit. Electrical soft starters can use solid state devices to control the current flow and therefore the voltage applied to the motor. They can be connected in series with the line voltage applied to the motor, or can be connected inside the delta () loop of a delta-connected motor, controlling the voltage applied to each winding. Solid state soft starters can control one or more phases of the voltage applied to the induction motor with the best results achieved by three-phase control. Typically, the voltage is controlled by reverse-parallelconnected silicon-controlled rectifiers (thyristors), but in some circumstances with three-phase control, the control elements can be a reverse-parallelconnected SCR and diode.

Another way to limit motor starting current is a series reactor. If an air core is used for the series reactor then a very efficient and reliable soft starter can be designed which is suitable for all type of 3 phase induction motor [ synchronous / asynchronous ] ranging from 25 KW 415 V to 30 MW 11 KV. Using an air core series reactor soft starter is very common practice for applications like pump, compressor, fan etc. Usually high starting torque applications do not use this method.

Contents

1 Applications 2 Motor and machine 3 Motor start-up o 3.1 Direct on-line starting o 3.2 Star-delta start-up o 3.3 Soft start-up 4 See also 5 References

Applications
Soft starters can be set up to the requirements of the individual application. In pump applications, a soft start can avoid pressure surges. Conveyor belt systems can be smoothly started, avoiding jerk and stress on drive components. Fans or other systems with belt drives can be started slowly to avoid belt slipping. In all systems, a soft start limits the inrush current and so improves stability of the power supply and reduces transient voltage drops that may affect other loads. [3][4][5]

Motor and machine

Across-the line starting of induction motors is accompanied by inrush currents up to 7 times higher than running current, and starting torque up to 3 times higher than running torque. The increased torque results in sudden mechanical stress on the machine which leads to a reduced service life. Moreover, the high inrush current stresses the power supply, which may lead to voltage dips. As a result, the operability of sensitive consumers may be impaired.[2]

Motor start-up
A soft start-up eliminates the undesired side effects. Several types based on control of the supply voltage or mechanical devices such as slip clutches were developed. The list provides an overview of the various electric start-up types. The current and torque characteristic curves show the behavior of the respective starter solution.

Direct on-line starting

Three-phase motor with low to medium power rating 3 conductors to the motor High starting torque High current peak Voltage dip One simple switching device

Star-delta start-up
Three-phase motor with low to high power rating Six conductors to the motor Reduced starting torque, 1/3 of the nominal torque High mains load due to current peak during switchover from Y to D High mechanical stress due to torque surge during switchover from Y to D Two or three switching devices, more maintenance

Soft start-up
Three-phase motor with low to high power rating 3 conductors to the motor Variable starting torque No current peak No torque peaks Negligible voltage dip One simple switching device Optional: Guided soft stop, protective functions, etc. Zero maintenance Compared to contactor solutions, soft starters, sometimes also referred to as soft starting devices, offer considerable advantages.

Torque surges entail high mechanical stress on the machine, which results in higher service costs and increased wear. High currents and current peaks lead to high fixed costs charged by the power supply companies (peak current calculation) and to increased mains and generator loads.

A soft starter continuously controls the three-phase motors voltage supply during the start-up phase. This way, the motor is adjusted to the machines load behavior. Mechanical operating equipment is accelerated in a gentle manner. Service life, operating behavior and work flows are positively influenced.

Braking chopper Space Vector Modulation