Automation Fair 2018 - T21 - Soft Starter or VFD-Which Is Best For Your Application

Soft Starter or VFD – Which Is Best for Your Application?
PUBLIC 2018 Automation Fair ® Event | #AutoFair18 | Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved.
Agenda
R EASON S FOR SOFT MOTOR STAR TIN G
MOTOR STARTING METHODS
AC DRIVES & SOFT STARTERS – WHAT MATTERS?
APPLICATIONS - GENERAL “RULES OF THUMB”
ADVANTAGES, DISADVANTAGES & SAVINGS
PUBLIC 2018 Automation Fair ® Event | #AutoFair18 | Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 2
Reasons for Soft Motor Starting
Minimize mechanical damage of

system components and product
Belts, gears, drive shafts, and keyways
Reduced product spillage
Fluid hammer and mechanical vibration
Reasons for Soft Motor Starting
Better Energy Management

Limits in-rush current
Meet power company requirements / rebate programs
Manage control under power distribution limitations
Energy cost reduction (peak demand charges)
Optimize the size of transformers / generators / switch gear
Two Main Reasons for Soft Starting:

- Minimize mechanical damage - Better Energy Management
Agenda
REASONS FOR SOFT MOTOR STARTING
MOTOR STAR TIN G METH OD S
Common Motor Starting Methods
Direct-On-Line (DOL) SMC™ (soft start) Variable Frequency Drive (VFD)
Simplest starting solution Simple starting and stopping Complete continuous control
at any speed
Full torque applied…motor Limited control at various speeds
Mechanical wear Full torque at any speed
≥6x inrush current Reduced torque and current without sacrificing current
during starting
Up to 17 different Unlimited starting possibilities

No starting choices starting/stopping modes when sized properly
Basic Advanced
Common Motor Starting Methods
Direct-On-Line (DOL) SMC (soft start) Variable Frequency Drive (VFD)
Limited functionality Simple…adjust and setup Highly efficient motor and

Unless used with application performance
Reduced installation costs
advanced overload Smaller footprint More complex setup and install
None to minimal need for Larger footprint
Finite mechanical life harmonic/EMC mitigation Impact on Power Quality
Contacts will wear out EMC remediation
Highly efficient when running at full speed
Application considerations
Energy saver performance for light loads Motors, wire types
Lead lengths, conditions
Common Motor Starting Methods include:

- Direct-On-Line (DOL) - Soft Starter (SMC) - Variable Frequency Drive (VFD)
Basic Advanced
How Does Direct-On-Line (DOL) Work?
Direct-On-Line (DOL) is also known as full voltage
Full Voltage Start and across-the-line starting
Full voltage, current, and torque “immediately”
Power is immediately removed when shut off
High starting torque can cause damage to mechanical system

High current can cause problems in the electrical system and can
also cause decreased system capacity
DOL starting means that the motor is started by connecting directly to the supply at rated voltage
How Does a Variable Frequency Drive (VFD) Work?
VFD (AC Drive) Variable Frequency Drives (VFDs) are also known as:
- Adjustable Speed Drives - AC Drives
- Adjustable Frequency Drives - Inverters
- Variable Speed Drives - Frequency Converters
VFD converts AC line voltage to DC voltage and then inverts it back to a

pulsed DC whose RMS value simulates an AC voltage
Most VFDs use a full wave diode-bridge or SCR rectifier bridge to convert the
AC line to DC voltage (DC bus)
Insulated Gate Bipolar Transistors (IGBTs) are used to invert the DC Bus
How Does a Variable Frequency Drive (VFD) Work?
VFD (AC Drive) Most common VFDs manufactured use pulse-width modulation (PWM) to
create the output sine-wave
During acceleration, the inverter applies different frequencies to the motor.

It also changes the voltage in proportion to the frequency (unlike SMCs)
The inverter produces rated torque from 0 to rated speed (unlike SMCs)
Inverter output can be any frequency below or above the line frequency --
up to the limits of the inverter or mechanical system. (unlike SMCs)
AC Drives control both the:

VOLTAGE and FREQUENCY applied to an AC motor.
How Does a Soft Starter Work?
SMC™ (soft Rockwell Automation® Soft Starters are called Smart Motor Controllers
(SMCs)
start)
3 pairs of back-to-back Silicon-Controlled Rectifiers (SCRs) are used to
start and stop the motor.
SCRS only, NO AC Front End, NO DC Bus, NO IGBTs
Back-to-back layout of SCRs allows control of AC line every half cycle

Regulates voltage from 0 volts up to line voltage.
Line frequency is not controlled.
SMC (soft start) Voltage controls the current and torque
The % change in motor torque is proportional to the square of the %
change in applied voltage
Current is directly related to the voltage applied to the motor
Voltage is ramped to full voltage or limited to provide current limited starts

Line frequency (50 / 60 Hz) is always applied to the motor
85% Voltage
50%Voltage
100% Voltage
SMC (soft start) 600%
510%
100%
(Amps)
%FLA
Torque
300%
72%
100%
Current 25% Full load
Torque
Torque required
0 by the load
Speed (RPM)
Soft Starters (like Rockwell Automation SMCs) control the VOLTAGE applied to an AC motor
Agenda
AC D R IVES & SOFT STAR TER S – WH AT MATTER S?
Did You Ever Wonder Why?
Worldwide, low-voltage AC Drives continue to be applied at the rate of

~20:1 versus Soft Starters
Even in situations where Soft Starters are sufficient to do the job?
Even when there can be substantial cost, size and energy savings
using a Soft Starter instead of an AC Drive?
Let’s Investigate
Why are AC Drives applied in situations in which Soft Starters are
sufficient to do the job?
AC Drives will work in almost all applications
Soft Starters will not work in all applications
Does this mean that AC Drives are easier to specify, install, and
commission than Soft Starters?
No
More things to consider when applying an AC Drive than applying a Soft Starter
A better way to examine this is that AC Drives work in a wider

variety of applications than Soft Starters.
Application, Application, Application!
When buying real estate “Location, Location, Location!”
When choosing a Soft Starter or an AC Drive

“Application, Application, Application!”
When deciding whether to choose a Soft Starter or an AC Drive for a particular
installation, application characteristics are the primary concern
The following must be carefully considered:

Torque requirements
Speed control needs
Power source / distribution considerations
Torque:
What are the load torque requirements?
Does the application need full torque at zero speed?
High Starting Torque? Holding Torque?
Does the application need constant torque?
Speed:
Does the application need speed control once the motor is at speed?
Is full speed reverse operation needed? Is slow-speed operation needed?
Is continuous speed feedback required? (position control)
Does the application need precise starting and stopping times?
Power Source:
Is the motor and power source undersized or closely matched?
Is the source voltage single-phase?
Other:
Is space a consideration?
Is thermal efficiency a primary concern?
When choosing a Soft Starter or AC Drive, the most important item is:
APPLICATION, APPLICATION, APPLICATION!
Agenda
APPLIC ATION S - GEN ERAL “R U LES OF TH U MB ”
“Rules of Thumb”
For Soft Starter applications general guidelines include:
Full speed operation
Reduction of mechanical wear and damage to system
Limiting current is prime reason for starting method
Lightly or moderately loaded applications
Lower starting torque applications
For AC Drive applications general guidelines include:

Speed control during the run mode
High starting torque
Position control
Holding rotor at zero speed
“Rules of Thumb”
When do I specify an AC Drive versus a Soft Starter (SMC)?
Speed Control is required
Consistent acceleration and deceleration times (New SMC™-50 exception)
High starting torque required
Continuous feedback (critical position control)
Custom start and stop maneuvers
Faster stopping with dynamic braking options
Drive can hold rotor a zero speed
Undersized or closely matched motor or power source
In order to apply these “Rules of Thumb” you need to know the:

Agenda
AD V AN TAGES, D ISAD VAN TAGES & SAVIN GS
Advantages and Disadvantages - Power Source
AC Drives can operate on most practical power supply

systems, including those that are closely matched to the
motor load
Typically, when using a soft starter, the supply source should

have the capacity to allow starting currents that are 150% to
450% of the motor load full load amperes
Some AC Drives can also operate 3-phase motor loads

using single-phase input power
Soft Starters can only operate on 3-phase input power
Advantages and Disadvantages - Installation Concerns
VFD – More installation items to consider
Impact on power quality
Harmonics, EMC Mitigation
Application considerations
Lead lengths, wire type

SMC – Limited installation items to consider
Harmonic / EMC Mitigation typically not needed
Lead lengths not a concern
Wye-Delta Motors (starting inside the delta):

VFD – Sized for line connected (three leads from motor), based on FLA of
motor
SMC – Can use smaller soft starter to start six lead motors inside delta
Advantages and Disadvantages - Torque
VFD –
100% torque available up to line frequency at motor base speed
Full torque is available at zero speed (holding torque)
Excessive current is not required for full torque
Both frequency and voltage are controlled
Above motor base speed torque decreases
SMC –
100% torque ONLY available once motor is up to speed and at full voltage
Frequency is fixed (line frequency only)
Only voltage is controlled
Advantages and Disadvantages - Speed Control
VFD – Continuous Speed Control
Both frequency and voltage are varied
Can achieve any output frequency from 0 Hz to X Hz
SMC – Full Speed Operation
Only voltage is controlled
SMC – Limited Slow Speed Operation
Short-term operation only (motor and application dependent)
SMC Flex - 2 fixed slow speeds (7% and 14%) with limited torque capability
- Forward and reverse without reversing contactor
SMC-50 - Adjustable slow speed (+/-1% - 15% of full speed) with improved torque
- Forward and reverse without a reversing contactor
Advantages and Disadvantages - Motor Rotation / Direction
VFD –
Continuous forward and reverse speed control
DC Bus voltage can be switched to create forward or reverse rotation in motor
Any frequency from 0 Hz to X Hz both forward and reverse is available
SMC –
Full Speed Operation (50 / 60 Hz)
Forward rotation direction depends on AC line phase orientation (A-B-C) or (C-B-A)
Reversing contactor is required for reverse full speed operation
Slow Speed Operation
Both forward and reverse slow speed operation available without a reversing
contactor (SMC™ Flex and SMC-50)
Limited speed operation
Advantages and Disadvantages - Starting and Stopping Time Accuracy
VFD – Speed control is precisely provided
Both frequency and voltage are controlled
Accurate starting and stopping times
SMC – Load Dependent
Only voltage is controlled (frequency is fixed - line frequency only)
Speed is estimated by measuring Motor Back EMF
SMC™-3 and SMC Flex
If up to speed is detected, then full voltage is applied
Start and stop times very load dependent
SMC-50
Sensorless linear acceleration / deceleration has much better speed
estimation
Much, much less load dependent
Accurate start and stop times
Advantages and Disadvantages – Motor Compatibility
AC Drives provide better performance than Soft Starters, but what performance is needed?
Savings
So why choose a Soft Starter?
Substantial savings can be realized when using a Soft Starter instead of an AC

Drive in the proper applications. (APPLICATION, APPLICATION, APPLICATION!)
Areas of Savings:
Cost
Physical size / volume
Energy
Cost Savings
“Typical” Cost Ratios of AC Drives versus Soft Starters:
(cost of AC drive / cost of Soft Starter)
Below 5 Hp (3.7 kW) 1.5...2.0

5 Hp (3.7 kW) to 50 Hp (37 kW) 2.0...4.0
50 Hp (37 kW) to 250 Hp (185 kW) 1.5...4.0
250 Hp (185 kW) to 500 Hp (375 kW) 3.0...4.5
Above 500 Hp (375kw) 2.5...5.0
Physical Size / Volume Savings
VFD – Larger than SMC at given current size
DC-bus power supply, DC Bus, and IGBTs are larger
than SCRs
Heatsinks are larger than internally bypassed SMCs
SMC – Smaller than VFD at given current size

SCRs are smaller than DC-bus power supply, DC Bus,
and IGBTs
Internally Bypassed SMCs are smaller than solid-state
SMCs
For internally bypassed units, heat is only a concern during
starting and stopping
Smaller, more compact heatsinks
Size differences can be large as Hp increases 33

Efficiency Savings
VFD – Typically 95% to 97% efficient

IGBTs in circuit
Energy savings capabilities are available
SMC – Internally bypassed units typically 99.5% efficient

SMC-3 and SMC Flex internal bypass contactor pulled in when at full speed
SMC – solid-state units typically 97% to 99% efficient
SMC-50 Energy savings capabilities are available
When operating at full speed and properly loaded, SMCs are more efficient than VFDs
Heat Savings
VFD
Active components always in circuit
IGBT, diodes/SCRs, are always in circuit and heat is generated
SMC
Internally Bypassed Units
SMC-3 and SMC Flex internal bypass contactor pulled in
Virtually no heat generated (current is across contactor)
Solid-state Units
SMC-50 is solid-state soft starter
SCRs are always in circuit and heat is generated
3 Main areas of savings when using an SMC:

- Cost - Physical size / volume - Energy
Summary and Conclusions
Application characteristics are important when choosing a Soft Starter or an AC Drive
(APPLICATION, APPLICATION, APPLICATION!)
Both a Soft Starter and an AC Drive can start a motor with reduced voltage and current, but
the unique characteristics of your application will dictate which is the best choice, allowing you
to right-size either a Soft Starter or AC Drive
No matter which motor control method you select, additional considerations for installation,
commissioning, and additional filters or circuit protection must be considered when specifying
a Soft Starter or AC Drive
Summary and Conclusions
Soft starters can yield significant COST, SIZE, and ENERGY savings over AC Drives if
selected properly (APPLICATION, APPLICATION, APPLICATION!)
AC Drives can be 1.5...5 times the cost of a Soft Starter
AC Drives can be 1.5...10 times the size of a Soft Starter
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Soft Starter or VFD – Which Is Best for Your Application?

R EASON S FOR SOFT MOTOR STAR TIN G

MOTOR STARTING METHODS

AC DRIVES & SOFT STARTERS – WHAT MATTERS?

APPLICATIONS - GENERAL “RULES OF THUMB”

ADVANTAGES, DISADVANTAGES & SAVINGS

Minimize mechanical damage of

Better Energy Management

Two Main Reasons for Soft Starting:

REASONS FOR SOFT MOTOR STARTING

MOTOR STAR TIN G METH OD S

AC DRIVES & SOFT STARTERS – WHAT MATTERS?

APPLICATIONS - GENERAL “RULES OF THUMB”

ADVANTAGES, DISADVANTAGES & SAVINGS

Up to 17 different Unlimited starting possibilities

Limited functionality Simple…adjust and setup Highly efficient motor and

Common Motor Starting Methods include:

High starting torque can cause damage to mechanical system

VFD converts AC line voltage to DC voltage and then inverts it back to a

During acceleration, the inverter applies different frequencies to the motor.

AC Drives control both the:

Back-to-back layout of SCRs allows control of AC line every half cycle

Current is directly related to the voltage applied to the motor

Voltage is ramped to full voltage or limited to provide current limited starts

REASONS FOR SOFT MOTOR STARTING

MOTOR STARTING METHODS

AC D R IVES & SOFT STAR TER S – WH AT MATTER S?

APPLICATIONS - GENERAL “RULES OF THUMB”

ADVANTAGES, DISADVANTAGES & SAVINGS

Worldwide, low-voltage AC Drives continue to be applied at the rate of

Even in situations where Soft Starters are sufficient to do the job?

Soft Starters will not work in all applications

A better way to examine this is that AC Drives work in a wider

When buying real estate “Location, Location, Location!”

When choosing a Soft Starter or an AC Drive

The following must be carefully considered:

REASONS FOR SOFT MOTOR STARTING

MOTOR STARTING METHODS

AC DRIVES & SOFT STARTERS – WHAT MATTERS?

APPLIC ATION S - GEN ERAL “R U LES OF TH U MB ”

ADVANTAGES, DISADVANTAGES & SAVINGS

For AC Drive applications general guidelines include:

In order to apply these “Rules of Thumb” you need to know the:

REASONS FOR SOFT MOTOR STARTING

MOTOR STARTING METHODS

AC DRIVES & SOFT STARTERS – WHAT MATTERS?

APPLICATIONS - GENERAL “RULES OF THUMB”

AD V AN TAGES, D ISAD VAN TAGES & SAVIN GS

AC Drives can operate on most practical power supply

Typically, when using a soft starter, the supply source should

Some AC Drives can also operate 3-phase motor loads

Soft Starters can only operate on 3-phase input power

Wye-Delta Motors (starting inside the delta):

Substantial savings can be realized when using a Soft Starter instead of an AC

(cost of AC drive / cost of Soft Starter)

Below 5 Hp (3.7 kW) 1.5...2.0

SMC – Smaller than VFD at given current size

Size differences can be large as Hp increases 33

VFD – Typically 95% to 97% efficient

SMC – Internally bypassed units typically 99.5% efficient

3 Main areas of savings when using an SMC:

AC Drives can be 1.5...5 times the cost of a Soft Starter

AC Drives can be 1.5...10 times the size of a Soft Starter