Continuous operation

Advanced

Integrated and Easy to install

Enhanced
future ready

Essential

Safety and protection

—
ABB CONSULTANTS TALKS- EP05- WEDNESDAY, 30 SEPTEMBER, 2020

Motor Starting, Protection and Control

Keep things moving with protection and control - at every level.
Amr Younis – Technical and Design Promotion Manager
—
Agenda

• Introduction
• Motor Protection and Control components
• Motor Staring Methods
• Direct Online
• Star-Delta
• Soft starters
• VSD’s
• Coordination of Protection

30 September,
Slide 2 MV
2020
—
Introduction
Motor Starting
—
Motor Starting Solutions
Why it‘s important

Compressor Ventilation Water pump

Compressor Ventilation Water pump

30 September,
Slide 4
2020
—
Motors Starting
Why it’s important?

42% 2/3 28%

of all electricity is used by of this is used by of global electricity
the industry electrical motors consumption

30 September,
Slide 5
2020
—
Motors Starting
Why it’s important?

300,000,000
electrical motors are currently
installed worldwide.

90% are used in full-speed

applications.

30 September,
Slide 6
2020
—
Motor starting
General characteristics

t [s]

Thermal protection

Tripping Class

Motor starting current Magnetic threshold

Ie I [A]
Ia=7.2xIe
Ip=12xIe

30 September,
Slide 7
2020
—
Motor Starting
Basic Motor Circuit Components
—
Motors Starting
Motor Protection & Control

- Disconnector
Isolation
- Switch disconnector

c
- Switch Fuse
Short Circuit Protection - Circuit Breaker (Magnetic)
- Manual Motor Starter

Control - Contactor

Overload Protection/ - Thermal Overload

Other protections - Electronic Overload
- Universal Motor Controller UMC

M
3~

30 September,
Slide 9
2020
—
Motor Starting
Isolation
—
Motors Starting
Isolators

Enclosed switches disconnector

Why is isolation required?
To separate the electrical (input) source from the motor starter
Engineers can carry out maintenance/troubleshooting on the
motor starter without risk of electrocution

30 September,
Slide 11
2020
—
Motor Starting
Control
—
Motors Starting
Contactors

AF Contactors
Electric switching device to control the operation
AF Contactors is used for switching ON and OFF motor loads
according to IEC 60947-4-1
The full range has the following advantages
– Wide range operating coil 100-250 VAC/Dc
– Built-in Surge Suppressor
– Distinct operation (ON-OFF)
– 75-80% saving in power consumption
– 15-20% Space saving

30 September,
Slide 13
2020
—
Essential solutions
Get the essentials right with fast, reliable installations

30 September,
Slide 14
2020
—
Continuous operation
Coil operating limits

IEC standard requirement Conventional coil AF coil

+10% 253V +10% 253V +10% 275V

Uc 230 V 230 V 250 V

-15% 220 V
-15%
187 V
187 V

100 V
-15%
85 V

30 September,
Slide 15 Uc = Control voltage
2020
—
Contactor duty cycle
Examples of contactor duty

Motor control
Current Current Current

In In In
10 seconds Time Time Time
Direct on-line start (AC-3) Star-delta start Inching (AC-4)
Making about 6 times nominal current Star contactor making 3 times Making 6 times nominal current
Breaking nominal current at opening nominal current Breaking 6 times nominal current
Other application examples
Current Current Current

In In In
Time Time Time
Heating resistance AC-1) Capacitor switching (AC-6b) Dynamic breaking: making short
Making/ breaking nominal current Making 100 times In or more time inrush current at cycle end

30 September,
Slide 16
2020
—
Contactors in AC Power circuits
Circuit diagram and main contacts arrangement

Houses = low power: 3 phase

– Single phase connection, and Neutral
load operated with a simple 230V 230V
Utilities LV 230V between 400V between
switch on the phase side
transformer phases and neutral each phase

Industry = high power: Simple switch or

single contact 3-pole contactor
– 3-phase connection and load
operated with a contactor
Earth
Earth connection
connection
Building, parking lots
illumination
– Three phase connection with
3-pole contactors Utilities LV 230V between Utilities LV Generating
– Sometimes single phase transformer phases and neutral transformer set
connection with 2-pole or
4-pole contactors
4-pole contactor 4-pole contactor
3-pole contactor
Generating set
– 3-phase + neutral changeover
with two 4-pole contactors Earth
connection

30 September,
Slide 17
2020
—
Motor Starting
Short Circuit Protection
—
ABB Short-Circuit Protection Elements
Short Circuit Protection

Circuit Breakers – Magnetic Only Switch Fuses Manual Motor Starters

Short Circuit Protection Only Short Circuit Protection Only Short Circuit only
Magnetic only or Electronic trip units Requires additional Overload protection Short Circuit and Overload Protection
Requires additional Overload protection 0.1-100 Ampere
Protection: 12-14 In

30 September,
Slide 19
2020
—
Manual Motor Starter
Standard/ Premium main differences

ABB’s standard range up to 32A ABB’s premium range up to 32A ABB’s premium range up to 65A
MS116 MS132/ MO132 MS165/ MO165

✓ IE3 ready ✓ IE3 ready ✓ IE3 ready

✓ World wide approvals
✓ Ics/Icu ratings up to 50 kA
✓ Coordination with AF contactors
✓ World wide approvals
✓ Ics/Icu ratings up to 100 kA
✓ Coordinations with AF contactors
✓ Trip position
✓ ATEX certified
✓ UL Type E/F ratings
✓ Combination motor controller
✓ World wide approvals
✓ Ics/Icu ratings up to 100 kA
✓ Coordinations with AF contactors
✓ Trip position
✓ ATEX certified
✓ UL Type E/F ratings
✓ Combination motor controller

30 September,
Slide 20
2020
—
Motor Starting
Overload Protection/Other protections
—
Overload relay
What is a trip class?

t
100
80
60
40
30
20 30
20
10
8 Trip curve
6 according to IEC
10
4 60947-4-1
3
2

1
2 3 4 6 8 10 20 30
7.2 Multiple of rated current

– Class 10: 4–10 s

– Class 20: 6–20 s
– Class 30: 9–30 s

30 September,
Slide 22
2020
—
ABB Overload Protection offering range
Overload Relays
Universal Motor Controller –
Thermal Overload - TF Electronic Overload - EF UMC100.3

Overload and phase failure protection
using Bimetal trip unit
Trip Class 10
0.1-200 Ampere
Country of Origin: Germany/China
Overload and Phase failure Protection Motor Protection
using Electronic trip unit Motor Control
Trip Class: Selectable 10-20-30 Motor Diagnostics
0.1-800 Ampere Communication
Country of Origin: Germany/China Country of Origin: Germany

30 September,
Slide 23
2020
—
Thermal overload relays
Basics TF series

Based on new technology

Marking
– Separate STOP button

– Trip Class 10
Current setting
– Operating temp. range -25 up to 60°C

– Manual/ automatic reset selectable Cover, sealable

– Test function
Reset button
– Sealable cover for current setting, reset selection and test
function
Test/ Status
– Perfect match to the contactor
indication
– Also available: ATEX certified types and kits for separate
mounting
Stop button

30 September,
Slide 24
2020
—
Electronic overload relays
Basics EF series

Based on electronic technology

Marking
– Separate STOP button

– Trip Class 10E, 20E, 30E selectable Current setting

– Operating temp. range -25 up to 70°C
Trip class
– Manual/ automatic reset selectable selection

– Test function Cover, sealable

– Sealable cover for current setting, reset selection and test

Reset
function
Test/ Status
– Perfect match to the contactor indication
– Also available: ATEX certified types and kits for separate
mounting
Stop

30 September,
Slide 25
2020
—
Advanced solutions
UMC100.3 application example

Connection to DCS, ABB Ability™

800xA and
gateway for ABB Ability™ EDCS
Manual motor
starter Voltage module

Universal Motor
Industrial Ethernet
Controller UMC100.3 • EtherNet/IP™
• Profinet IO Universal
• Modbus TCP Motor Controller
UMC100.3 Digital module
Fieldbus
• Modbus RTU
• DeviceNet™ AF contactors
• Profibus DP

Analog /
temperature module

30 September,
Slide 26
2020
—
Motor starter examples
Stand alone or combined

 Disconnect  Disconnect  Disconnect

 Short-circuit  Short-circuit  Short circuit
protection protection protection
 Overload  Overload  Manual control
protection protection
 Phase-failure  Phase-failure
 Manual control  Manual control

 Control

 Control  Overload
protection

30 September,
Slide 27
2020
—
Motor starting
Control (On/Off) operation and Indication

Starter ON

or +
Start Stop
Pushbutton Pushbutton
Starter OFF
Motor Starter Control AF Contactor

or or
Starter Tripped

Overload Relay Manual motor

starter
Circuit breaker Motor Starter Indication

30 September,
Slide 28
2020
—
Motor Starting
Direct Online Starters
—
Motors Starting
Electrical and Mechanical Characteristics

T High inrush current

Tst/ Tn 1,5…2,5
High torque during start Terminal box

Tn

Drive shaft Cooling fan

n
I 7*In
Stator
windings

In (FLA) Rotor
Stator

n
Nominal speed

30 September,
Slide 30
2020
—
Motors Starting
Motor Protection and Control

Direct Online Starters

- Traditional starting method
- Full voltage with no control of the start
- Compact and cost efficient solution
- Mostly used for small motors

Potential electrical problems

- Warm cables
- Tripping breakers

Potential mechanical problems

- Slipping belts
- Heavy wear and tear
- Damaged products

30 September,
Slide 31
2020
—
Motor Starting
Star Delta Starters
—
Motors Starting Methods
Star-Delta Starter

General Characteristics
- Low starting current (only at successful start)
- Transmission peaks at loaded start
- Low starting torque (often too low)
- Long starting time Delta Contactor

- Always direct stop

- Many devices – complex wiring Star Contactor

- Double motor cables

Line Contactor

30 September,
Slide 33
2020
—
Motor Starting
Soft Starters
—
Motors Starting Methods
Soft Starters (Starting and Stopping)

Short circuit
protection device
General Characteristics
- Adjustable starting current Line
- Correct starting torque matching the need Contactor

- Possibility to soft stop

- Medium long starting time
Softstarter
- Minimum mechanical wear.

Built in
Electronic
overload

Built in
By-pass

30 September,
Slide 35
2020
—
Soft starters
Principal Function

Theory of Operation

Anti-parallel connected thyristors Voltage reduction during starting

30 September,
Slide 36
2020
—
Soft Starters
Principal Function

Theory of Operation

U I T
100%

U = 50% I = 50%
T = 25%

t rpm rpm

https://new.abb.com/drives/softstarters/software-and-tools

30 September,
Slide 37
2020
—
Soft Starters
Sometimes the benefits are really obvious

Conveyor Belts Water Hammering

https://www.youtube.com/watch?v=DFCDAsd6Hd4 https://www.youtube.com/watch?v=NGZd6DZw-IE

30 September,
Slide 38
2020
—
Soft Starters
ABB Portfolio

PSR - Basic Range PSE – Mid Range PSTX – Advanced Range

• 3 - 105A • 18 - 370A • 30 - 1250A

• Built in bypass. • Built in bypass. • Built-in bypass.

• Flexible mounting. • User friendly HMI • User friendly and

detachable HMI
• Optional • Torque control.
communication. • Basic and advanced
• Current limit (1.5-7*Ie) protection functions.
• Connection kits for
• Basic motor protection Motor Heating.
Easy mounting with •
functions.
ABB MMS. • Pump Cleaning
• Analogue output.
• Limp Mode
• Optional
communication • Motor Jogging and
Breaking
• Torque Control

30 September,
Slide 39
2020
—
PSTX Softstarters
Why to use internal Bypass contactors

It’s the latest technology! Reducing Panel size Limp Mode

3-phase control 2-phase control

Reverse Staring and Pump cleaning
It’s not any option any more not to
use the bypass contactor
• Eliminate harmonics effect
• Decrease heat generation
• Increase thyristors lifetime

https://www.youtube.com/watch?v=Gp4Rvj-c9Dc

30 September,
Slide 40
2020
—
Motor starting solutions
Different ways to start a motor

DOL Y/D Softstarter

T T T

16 x FLA rpm rpm rpm

8 x FLA 8-16 x FLA

I I I

2,5-5 x FLA

rpm rpm rpm

30 September,
Slide 41
2020
—
Soft Starters
Parallel and Sequential Starting

Parallel Starting Sequential Starting

30 September,
Slide 42
2020
—
Motor Starting
Variable Speed Drives
 —
Motors Starting Methods
Variable Speed Drives
https://www.youtube.com/watch?v=E0BattO-NAs
General Characteristics
- Full control of speed, current and torque
- Energy saving from reducing speed
- Mostly used for process control
- No Value for full speed applications AC
- Creates Harmonics DC
- Heat Dissipation
speed
DC
AC

time M

30 September,
Slide 44
2020
—
Motors Starting Methods
Variable Speed Drives

https://www.youtube.com/watch?v=cap0baKxnwc

30 September,
Slide 45
2020
 PRODUCT OVERVIEW

—
Motion
Drives

Low Voltage Drives

• Low voltage AC 0.75 to 5600 kW

• Low voltage DC 7.5 kW to 4.8 MW
• Industrial drives
• Industrial specific drives 0.37 to 400 kW
• Drives for HVAC
• Drives for Water
• Micro drives 0.18 to 4 kW
• Machinery drives 0.18 to 560 kW
• General purpose drives 0.75 to 355 Kw
• Motion control products 0.75 to 160 kW

30 September,
Slide 46
2020
 —
The motor starting market
Which starter shall be select

Full speed Constant speed Variable speed

Un-controlled start “Semi-controlled “start Controlled start

Medium voltage/High power etc.

Single phase motors,
small motors, etc.

DOL Y/D Softstarter Drive

Small motor ratings Higher ratings All ratings

Overlap

30 September, Slide 47 This picture doesn’t represent any actual size of market, it just a visualization to explain the market split
2020
—
Motor Starting
Coordination of Protection
—
Motors Starting
Coordination of Protection

Coordination type 1 Coordination type 2

- No risk for operators or installations - No risk for operators or installations

- Isolation is kept after inrush - Isolation is kept after inrush
- Before re-starting, starter repairing is necessary - The starter is still working after short-circuit
- Other apparatus than contactor and overload relay shall not - Before re-starting, a quick inspection is sufficient
be damaged - Light welding of contacts is allowed if they could be easily
- Cheaper separated (by electrical operation or tool)
- Require more maintenance - Higher device size
- More economic in maintenance and parts

30 September,
Slide 49
2020
—
Motors Starting
Coordination Types

https://applications.it.abb.com/SOC/page/selection.aspx

30 September,
Slide 50
2020
—
Soft Starters
Coordination of Protection

Coordination Type 2 for Soft starters

Semi-conductor fuses (High speed fuses) are the only type of

fuses that are fast enough to achieve a fully type 2 coordination
when using a soft starter. A separate overload relay for the motor
protection is always required in combination with this type of
fuse. If replacing the semi-conductor fuses with an MCCB, MMS
or similar, type 1 coordination will be achieved instead.

30 September,
Slide 51
2020