Transcript Rockwell Automation External LTS Template

Motor Starting
Technologies
Jack Smith – SYD
Joe Pickell - RA
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
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Objective
• Review the basic motor starting technologies:
– Across the line
– Reduced voltage
– Variable frequency
• Understand the selection criteria for each technology
• Review application considerations for each starting technology
–
–
–
–
Relative cost
Effects on available torque
Maintenance issues
Reliability
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
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Across The Line Starters
• Electromechanical or Solid State switch that closes the motor power circuit.
– Motor is either on or off
• Various design standards exist for contactors
– NEMA
– IEC
– Definite Purpose
• Characteristics
– Motor has full voltage available as soon as power circuit closes
• Pulls an inrush current 5-7X Normal running current
• Motor can produce full torque immediately
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3
Across the Line Starter - NEMA
Advantages
•Available up to NEMA size 9, 1600HP @480VAC, 2250A
•Simple design, few moving parts, reliable
•Proven durability
•Versions tested for various applications
•Field serviceable
•UL and CSA approved
•Allen Bradley tested to 10 million operations
Limitations
•Not touch safe
•Physically large
•Panel must be drilled and tapped to mount
•Cannot be mounted significantly off vertical
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Across the Line Starter - IEC
Advantages
•Available up to 860A, AC-3
•Modular family includes:
•Overloads
•MSP’s
•Mounting Systems/Busbars
•Touch safe design
•Versions tested for various applications
•Space saving designs, mini versions available
•DIN rail mounted
•Global approvals
Limitations
•Life span is application dependent
•Typically 1 million operations at rated load
•Limited field serviceability
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IEC vs. NEMA Cost / Size / Life Comparison
Data
Description
NEMA
Size 1
IEC 18 Amp
AC-3
HP Rating
10HP
10 HP
Life Operations
10 mil
2 mil
List Price
$204
$130
Panel Area Required 21.4 in2
7.1 in2
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Life Comparison Equalizing Life
Data
Description
NEMA
Size 1
IEC 18 A
AC-3
IEC 38 A
AC-3
HP Rating
10HP
10 HP
25HP
Life Operations
10 mil
2 mil
10 mil
List Price
$204
$130
$210
7.1 in2
14 in2
Panel Area Required 21.4 in2
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Across the Line Starter – Definite Purpose
Advantages
•Available up to 90A, 1,2or 3 pole versions
•Specially tested to HVAC standards
•Fast-on connections
•DIN rail mounting available
•Economically priced approx. 2/3 IEC $
•UL and CSA approvals
Limitations
•Life span is application dependent
•Panel normally drilled and tapped
•Very limited field serviceability
•No matching overloads
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Across the Line Starter – Solid State
Advantages
•Available up to 50A, AC-1 or 15A, AC-3
•No moving parts
•Touch safe design
•Ideal for high duty cycle or high vibration applications
•Ideal replacement for mercury contactors
•DIN rail mounted
•Global approvals
Limitations
•Heat dissipation can be an issue
•No field serviceable parts
•No matching overloads
•No aux contacts
•Approx 1.5x IEC $
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Across the Line Starter – Vacuum
Advantages
•Available up to 500HP @ 480 VAC, 600A
•Long contact life due to vacuum
•Ideal for high duty cycle applications
•UL, CSA approvals
Limitations
•Physical size may be an issue
•Approx. 2x IEC $
•Limited offering starting at 200A
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Overload Relays for ATL Starters
Overload
Protection
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Comply with NEC/CEC
 Motor running overcurrent
protection
 NEC article 430 - part C
 CEC rule 28-200
 Reduce fire hazard
NEC Article 430
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Eutectic Alloy Type
• Adjust trip setting by installing
various rated heater elements
• Manual Reset only
Type W
Heater Elements
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Eutectic Alloy
Type W
Heater
Elements
Resistance Element
Thermal Mass
To Motor
To Power
Pawl to Mechanism
Which Controls Relay
Contacts
Thermal
Ratchet Stud
Memory
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Eutectic Alloy Overload Relay Operation
EUTECTIC ALLOY
POWER
CIRCUIT
RATCHET
POWER
CIRCUIT
HEATER
PAWL
TO
STARTER
COIL
PIVOT
TO
STARTER
COIL
CONTACT
ACTUATOR
CONTROL
CIRCUIT
CONTROL
CIRCUIT
Reset Position
Tripped Position
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15
Bi-Metal Theory
Bi Metallic
 Two metals with dissimilar expansion
 Generated heating causes deflection
 Adjustable trip setting
 Manual or automatic reset
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Basic Electronic Overload
Advantages
• Increased accuracy
• Enhanced performance
• Easy to select and apply
• Greater application flexibility
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Product Overview
Feature Overview
Insert Molded
Power Stabs
Latching Mechanism
Test Button
Reset Button
Mechanical Trip
Actuator
DIP Switches
(193-EE, 592-EE only)
Trip Status
Indicator
FLA Setting Dial
Control Terminals
95 & 96 / 97 & 98
Load Terminations
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Product Overview
Wide 5:1 Adjustment Range
• Application flexibility
• Simplified product selection with a minimized number of catalog devices,
greater overlap
• One device covers the range of 4 bimetallic overloads or 19 eutectic
heater elements
E1 Plus
Bimetal
0.1A
90A
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Proper Overload
Protection
vs.
Motor Life
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Reduced Voltage Starters
• Basic Functionality
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Reduce inrush current during motor start
After start motor runs at full rated speed
Reduced starting torque = reduced mechanical wear
May provide energy savings if peak charges are an issue
• Electromechanical
– Part Winding
• Used with special motors with parallel windings
• Reduced starting torque
– Wye – Delta
• Used with 6 lead delta wound motors
• Reduced starting torque
– Autotransformer
• Reduced starting torque vs. ATL but most per amp of above
• Solid State
– Uses SCR’s to chop voltage peaks during start up
– Electronic controls on SCR’s enable flexible starting profiles
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Economy Solid State Soft Starts
Advantages
• Up to 100HP @480VAc, 135A
•Start ramp time selectable from 2 – 30 sec
• Initial torque can be selected from 15% to 65%
• Kick start can be selected to provide breakaway torque
• Built in Overload protection
• Diagnostics via flashing LED
• Remote status via alarm contact
• Ramp to stop
Limitations
• No field serviceable parts
• Limited starting torque
• 4 – 10 starts per hour
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Full Featured Solid State Soft Starts
Advantages
• Up to 400HP @ 480VAC, 480A
•Programmable ramp time
• Special pump control algorithm available
• Preset slow speed capable
• Can do full voltage start
• Built in Electronic Overload protection
• Diagnostics via local message display or comms
• Remote status via alarm contacts or comms
• Smart motor braking optional;
Limitations
• Limited starting torque
•
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Variable Frequency Drives
• Basic Functionality
– Offers total speed control including ramp
up and down
– Speed controlled by changing frequency of
power to motor
– Speed control may result in energy
savings
• Component class drives
– Power Flex 4
– Power Flex 40
– Power Flex 400
• Architecture Class Drives
– Power Flex 70
– Power Flex 700
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“Component Class” Drives
Optimized for machine-level and stand-alone control
“4-Class”
Products
Performance / Functionality
• Most economical
Allen-Bradley
offering in its power,
performance &
feature segment
• Simple selection,
set-up, & operation
• Industry-standard
RS-485
communications
capabilities
• Industry-standard
power structure
features &
installation options
PowerFlex 40
PowerFlex 400
PowerFlex 4
5
10
20
50
100
Power Rating (HP @ 460V)
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200
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Component Drive Applications
• Provides a smooth accel/decel –
no jerky motion
• Fixed acceleration using variable
frequency
– Important when synchronizing machines or
processes
• Speed changes “on the fly”
• Communication status across network
• Critical stopping criteria –
– For repeatable and accurate “in position”
applications
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Rockwell Automation Strengths
• The most simple to use product in its class
• Integral keypad with control keys and local pot active out of the box
• DIN rail mounting, small package size, Zero Stacking
• Same integral keypad as PowerFlex 4
• Expanded I/O, sensorless vector control, add on communications options
and timer/counter/Step Logic functionality
• PowerFlex 400 is the HVAC drive with standard features
aimed at the centrifugal pump and fan marketplace
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Integral LED Keypad Simplifies Start Up
• 4 digit LED display indicates parameter number
or value
• LED indicators for run and direction status
• LED indicators for units of parameter values
• Programming keys similar to all other PowerFlex
products
• Three simple programming groups
– Display Group
– Basic Group
– Advanced Group
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Drive Commissioning Made Simple
•
Just hook up your power wiring and control the
drive from the integral keypad
– Control keys are active allowing out of the box
operation. Status indicators above start key and
speed pot indicate when active.
•
10 most common application parameters
contained in Basic Program Group to simplify
programming
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P031 Motor Nameplate Voltage
P032 Motor Nameplate Frequency
P033 Motor Overload Current
P034 Minimum Frequency
P035 Maximum Frequency
P036 Start Source
P037 Stop Mode
P038 Speed Reference
P039 Accel Time 1
P040 Decel Time 1
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PowerFlex 40 – Increased Performance
• Excellent motor control, thru 7.5 kW / 15 HP
– V/Hz or Sensorless Vector (SVC) modes
• Communication
– Integral RS485 serial communication
– Add-on communication adapters
• Expanded I/O
– Analog output
– 2 digital outputs
• Logic Functions
– Timer
– Counter
– StepLogic
• Similar to PowerFlex4
− Common parameter structure & set-up
– Integral user interface
– Common “4 Class” accessories
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Relative Cost Comparison 5-50HP
5HP
15HP
30HP
50HP
DP
IEC
0.7
0.6
0.8
0.9
1.0
1.0
1.0
1.0
SS
NEMA Contactor
2.3
3.4
4.5
2.2
1.5
1.0
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SS
Reduced
Voltage
VFD
3.7
3.1
3.8
4.3
8.0
11.8
8.5
13.0
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Relative Cost Comparison 75 – 200HP
IEC
75HP
100HP
150HP
200HP
1.0
1.0
1.0
1.0
NEMA Vacuum
3.9
2.4
3.1
2.7
5.5
3.3
2.0
3.1
SS
Reduced
Voltage
VFD
5.5
4.4
3.1
3.0
12.9
9.6
8.0
11.2
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Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
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Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
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