INDEX

1. Introduction 1

2. AC Induction Motors 1

3. Slip Ring Motors 1

4. Synchronous Motors 2

5. Torque And Horsepower 2

6. Motor Starting 3
 Problem During Starting
 Solution

7. DOL Starter 3

8. Need Of Soft Starter 4

 Mechanical Shocks
 Utility Restrictions
 Torque Requirements

9. Various Methods Of Motor Starting 4

10. Selection Of Appropriate Starting System 5

 Autotransformer Starting
 Star-Delta Starter
 Soft Starter

A] Reactor Soft Starter

 Coreless Reactor
 Iron Core Reactor

B] Electronic Soft Starter

11. Reactor Soft Starter Special Edition Pages 10

12. Reactor Design 10

13. References And Other Information 12

14. Design Your Own Soft Starter 13

Introduction

Today, Motors are the heart of any industry. We can't imagine our industry without a motor and as the motors are
the prime movers and have become back bone of any industry, it has become equally important to take care of
these industrial work horses. Here in the following chapters, we will be covering various methods and techniques
about the motor starting, its need and benefits. Let us begin with some basic information about the AC motors.

AC Induction Motors

AC induction motors are ideal for most industrial and commercial applications because of their simple
construction and less number of parts which reduce the maintenance cost. Induction motors
are frequently used for both constant-speed and adjustable speed drive (ASD) applications.

The two basic parts of an induction motor are the stationary stator located in the motor frame and the rotor that
is free to rotate with the motor shaft. Today's motor design and construction are highly refined. For example,
stator and rotor laminations have been designed to achieve maximum magnetic density with minimum core
losses and heating. The basic simplicity of this design ensures high efficiency and makes them easily adaptable
to a variety of shapes and enclosures.

A three-phase induction motor can best be understood by Plot representing the three phase currents displaced by 120 electrical degrees
examining the three-phase voltage source that powers 1

the motor. Three-phase currents flowing in the 0.8 Phase a Phase b Phase c
motor(shown in figure 1.) establishes a rotating magnetic 0.6
field in the stator coils. This magnetic field continuously
0.4
pulsates across the air gap and into the rotor. As magnetic
Current magnitude

flux cuts across the rotor bars, a voltage is induced in 0.2

them, similar to a voltage induced in the secondary 0

winding of a transformer. As the rotor bars are part of a
-0.2
closed circuit (including the end rings), a current begins to
circulate in them. The rotor current in turn produces a -0.4

magnetic field that interacts with the magnetic field of the -0.6

stator. Since this field is rotating and magnetically -0.8

interlocked with the rotor, the rotor is dragged around with
-1
the stator field. When there is no mechanical load on the 0 1 2 3 4 5 6 7
Time displacement
motor shaft (no-load condition), the rotor almost
manages to keep up with the synchronous speed of the Fig.1
rotating magnetic field in the stator coils. Drag from bearing friction and air resistance prevents perfect
synchronism. As the load increases on the motor shaft, the actual speed of the rotor tends to fall further behind
the speed of the rotating magnetic field in the stator. This difference in speed causes more magnetic lines to be
cut, resulting in more torque being developed in the rotor and delivered to the shaft mechanical load. The rotor
always turns at the exact speed necessary to produce the torque required to meet the load placed on the motor
shaft at that moment of time. This is usually a dynamic situation, with the motor shaft speed constantly
changing slightly to accommodate minor variations in load. The rotor consists of copper or aluminum bars
connected together at the ends with heavy rings. The construction is similar to that of a squirrel cage, a term
often used to describe this type of AC induction motor.

The squirrel cage induction motor is most commonly used because of the following reasons
• Simplicity
• Rugged construction
• low manufacturing cost

Slip Ring Motors

Slip ring motors or wound rotor motors are a variation of the standard cage induction motors. The slip ring motor
has a set of windings on the rotor which are not short circuited but are terminated to a set of slip rings for
connection to external resistors and contactors. The slip ring motor enables the starting characteristics of the
motor to be totally controlled and modified to suit the load. A particular high resistance can result in the pull out
torque occurring at almost zero speed, providing a very high locked rotor torque at a low locked rotor current. As
the motor accelerates, the value of the resistance can be reduced by altering the start torque curve in such a
manner that the maximum torque is gradually moved towards synchronous speed. This results in a very high

1
starting torque from zero speed to full speed at a relatively low starting current. This type of starting is ideal for
very high inertia loads allowing the machine to get to full speed in the minimum time with minimum current
drawn.

The drawback of the Slip Ring Motor is that the slip rings and brush assemblies need regular maintenance which
is an additional cost not applicable to the standard cage motor. If the rotor windings are shortened and a start is
attempted, i.e the motor is converted to a standard induction motor, it will exhibit an extremely high locked rotor
current, typically as high as 1400% and a very low locked rotor torque, perhaps as low as 60%. In the case of
most applications, this is not a suitable option.

Synchronous Motors

The construction of the Synchronous Motors is essentially similar to the construction of the salient- pole
alternator. In fact, such an alternator may be run as an AC motor. Synchronous motors have the characteristic of
constant speed between no load and full load. They are capable of correcting the low power factor of an inductive
load when they are operated under certain conditions. They are often used to drive DC generators. Synchronous
motors are designed in sizes up to thousands of horsepower. They may be designed as either single-phase or
multiphase machines.

To understand how the synchronous motor works, assume that the application of three-phase AC power to the
stator causes a rotating magnetic field that gets set up around the rotor. The rotor is energized with DC (it acts
like a bar magnet). The strong rotating magnetic field attracts the strong rotor field activated by the DC. This
results in a strong turning force on the rotor shaft. The rotor is therefore able to turn the load as it rotates in step
with the rotating magnetic field. It works this way once it's started. However, one of the disadvantages of a
synchronous motor is that it cannot be started from a standstill by applying three-phase AC power to the stator.
When AC is applied to the stator, a high-speed rotating magnetic field appears immediately. This rotating field
rushes past the rotor poles so quickly that the rotor does not have a chance to get started. In effect, the rotor is
repelled first in one direction and then in the other. A synchronous motor in its purest form has no starting
torque. It has torque only when it is running at synchronous speed. A squirrel-cage type of winding is added to
the rotor of a synchronous motor for it to start.

To start a practical synchronous motor, the stator is energized, but the DC supply to the rotor field is not
energized. The squirrel-cage windings bring the rotor to near synchronous speed. At that point, the DC field is
energized. This locks the rotor in step with the rotating stator field. Full torque is developed and the load is
driven. A mechanical switching device that operates on centrifugal force is often used to apply DC to the rotor as
synchronous speed is reached. The practical synchronous motor has the disadvantage of requiring a DC exciter
voltage for the rotor. This voltage may be obtained either externally or internally, depending on the design of the
motor. A Soft Starter can be used to start synchronous motor in a same way as the Squirrel cage motor is
started, but during this, the motor has to be in no load condition

Torque and Horsepower

Torque and horsepower are two very important

characteristics that determine the size of the motor for a 7 x FLC Full Voltage Stator Current
CURRENT (%Motor Full Load Current)

particular application. Torque is the turning effort. For

TORQUE (% Motor Full Load Torque)

example, suppose a grinding wheel with a crank arm 6 x FLC 2 x FLT

one-foot long takes a force of one pound to turn the

5 x FLC
wheel at steady rate, The torque required is one pound
times one foot or one foot-pound. If the crank is turned 4 x FLC Full Voltage Start Torque
twice as fast, the torque remains the same. Regardless of
how fast the crank is turned, the torque is unchanged as 3 x FLC 1 x FLT

long as the crank is turned at a steady speed. 2 x FLC

The discussion so far has only involved torque at a steady 1 x FLC

Sample Load Torque
speed. More effort is required to start a load than to keep
it going. An AC induction motor is built to supply the extra 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
torque needed to overcome the inertia of starting a load. ROTOR SPEED (%Full Speed)
The speed-torque curve for a representative motor is
shown in Figure 2 and illustrates that the starting torque Fig.2
is 250% of rated-load torque.

2
Motor Starting

From the figure one, we have seen that , whenever any AC motor is started on DOL, it generates a very high
starting torque, and draws a very large current, typically 6 to 8 times of its rated full load current. In most of the
applications, such a high starting torque is not required and reducing the starting torque and the current has
many benefits which are explained later.

Problem during starting

Full voltage starting of motors can produce objectionable voltage flicker, mechanical stress to its
connected load. For example, gear boxes or belt drive systems .It also creates pressure surges or water hammer
in pumping applications. Starting a motor at reduced voltage can help to reduce or overcome these problems.
But one should always remember that if the load cannot be accelerated to full speed using full
voltage and current, it cannot be accelerated to full speed using reduced voltage and current.

The selection of a suitable starting method for a motor/load combination is becoming increasingly important as
additional loads are added to existing utility and distribution systems.

Solution

There are several factors to be considered while selecting the starting equipment for any electric motor driven
load. These include:
1. The source of power and the effects, the motor starting currents will have on the source and the stability
of the system voltage.
2. The starting and breakdown torque characteristics of the motor (motor speed torque characteristics)
3. The motor starting characteristics (torque) that correspond to the motor best suited to the load
characteristics at full load and speed.
4. The starting characteristics of motor torque, load torque, accelerating load torque (load inertia) the motor
acceleration and running torque of the driven load.
5. The available short circuit capacity of the distribution system.
6. Process considerations: shock, vibration, mechanical hammer, the control and maintenance of different
starting methods.
The initial inrush currents, locked rotor currents and the resulting torque values produced are the factors that
determine whether the motor can be applied directly across the line, or whether the current has to be reduced to
get the required performance to match the load requirements and/or utility line voltage flicker or voltage dip
specifications.

DOL starter
7 x FLC Full Voltage Stator Current
CURRENT (%Motor Full Load Current)

Full voltage starting can be used whenever the driven

TORQUE (% Motor Full Load Torque)

load can withstand the shock of instantaneously applied 6 x FLC 2 x FLT

full voltage to the motor and where line disturbances can

5 x FLC
be tolerated. Full voltage starting uses a main contactor
to apply the motor stator windings directly across the 4 x FLC Full Voltage Start Torque
main system voltage. This type of starting method
provides the lowest cost, a basic and simple design of 3 x FLC 1 x FLT

controller, resulting in low maintenance and the highest

2 x FLC
starting torque.
Typically, this type of starting is called as direct online 1 x FLC
Sample Load Torque
starting, or DOL starting.
The current and torque curves for DOL starting are as
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
shown in figure 3. ROTOR SPEED (%Full Speed)

Fig.3

3
Need of Soft starter

Reduced voltage starting is required when a full voltage starting creates objectionable line disturbances on the
distribution system or where reduction of mechanical stress to gear boxes or belt drive systems is required.
It must be noted that when the starting torque will decrease proportionally to the percent square of voltage
applied (i.e. 50% voltage produces 25% torque =0.50 squared). This phenomenon also occurs in the
opposite manner when the voltage is increased.
There are three main reasons to apply reduced voltage to motors:
1. To reduce the mechanical jerks during starting and stopping
2. To limit the inrush current inherent with full voltage starting
3. To reduce the effects of pressure surges and water hammer in pumping systems.

Mechanical Shocks

This reason for applying reduced voltage has various different names; it can be called mechanical shock,
mechanical stress, or various other names. The effect is the same. When a motor is started at full voltage, the
torque being applied from the motor to the driven load rises to a very high value almost immediately. This can
cause damage to the bearings in the motor or the load, the rotor of the motor or to the mechanical coupling
method which connects the motor to the load. The load itself can sustain damage depending on what the
application may be. In the case of conveyor application, if the load is started too quickly,
the belts of the conveyor can be stretched or broken. If the motor is connected to the load via
chains or belts, these coupling means can be damaged as well by sudden starting techniques.

Utility Restrictions

As utility power systems continue to be run at maximum capacity, the effect of starting motors across the line
can put stress on the factory's power distribution system. The lights go dim, process control systems can fail or
trip out or you may be restricted as to when and how often you are allowed to start the motor.

Torque Requirements.

It is important to understand that when the voltage is reduced while starting a motor, so are the current and
torque values. It should be apparent that a motor that will not start a load at full voltage, it will not start that
same load under reduced voltage conditions. This conflict between torque and current requirements of induction
motors is one typical dilemma facing the user of reduced voltage starting equipment. It may be only one of
several problems but is the most common and most important.

Reduced voltage starting can be accomplished in several different ways.

VARIOUS METHODS OF MOTOR STARTING

To start a motor the following methods are usually adopted as per the size & application of motor.

1) DOL

2) Autotransformer

3) AC Drive (not recommended for fixed speed motors)

4) Star Delta Starter

5) Reduced voltage Soft Starter

4
Selection of Appropriate Starting System

The selection of an appropriate starting system requires the reviewer to compare or weigh the importance of
several factors.

Cost and Economics:

When determining the starting method, the economics of the decision can also provide important tips to the
selection of an appropriate controlling means.

Maintainability:

The capabilities of the mechanical and electrical support facilities and personnel can have an important
impact on the starting method determination

Physical size restraints:

The limitations of available physical floor space could be a major concern when retrofitting
new equipment into an existing control area. The physical construction of equipment
housing the newer technology may not be suitably incorporated within existing facilities. Careful
consideration may be required for the removal of heat generated by semi-conducting
devices, printed circuit cards, transformers and other electronic control devices. Cooling systems may be
needed to aid in the maintenance of a suitable environment for these types of equipment.

Ease of use:

One consideration that is sometimes overlooked is the capabilities of the personnel required to service and
maintain the equipment. Simpler more traditional starting means may be suitable where basic personnel
training levels are maintained. The simpler relay control logic systems may be adequate for the system
configuration required for the specific process.

1] DOL stating is already mentioned in this document, with starting curves as shown in figure 2.

2] Autotransformer Starting

Autotransformer starting automatically switching between taps of an autotransformer reduces the voltage,
current and torque to the motor according to the tap setting used on the autotransformer. There are two very
distinctive characteristics of an autotransformer starter.

1. The motor terminal voltage is not a function of load Autotransformer Starter on 50% Tap Torque (%FLT)
current and remains constant during the
800
acceleration time.
250
2. Due to the turn ratio advantages, the primary line 700
current is less than the secondary motor currents. A
three-coil autotransformer is connected in a wye 600 200

configuration and connected to the motor in such a

500
way as to supply reduced voltage to the motor when
150
the line voltage is applied to the Autotransformer. 400
Several sets of taps are usually available to the user to
provide different values of reduced voltage. (NEMA 300 100

standards are 80%, 65% and 50% of the full line Start Current
200
voltage). But, auto transformer starter suffers form Start Torque
50
various drawbacks as mentioned below. 100
Load Torque
a] It has mechanical components for changing of taps
and hence it requires frequent maintenance and 0
10 20 30 40 50 60 70 80 90
inspection.
Rotor Speed (%)
b] Voltage applied to the motor terminals is in step
manner and not continuous. Hence, voltage flickers Fig.4
and mechanical jerks are a part of auto transformer starting.
c] A very dangerous spike, as shown in figure 4 is experienced by the system during starting.

5
3] Star-Delta starter

The Star Delta Starter can be used only with a motor which is rated for connection in delta operation at the
required line voltage, and has both ends, each of the three windings available individually. At Start, the line
voltage is applied to one end of each of the three windings, with the other end bridged together, effectively
connecting the windings in a star connection. Under this connection, the voltage across each winding is 1/ 3 of
line voltage and so the current flowing in each winding is also reduced by this amount. The resultant current
flowing from the supply is reduced by a factor of 1/3 as is the torque. i.e. A motor which exhibits a LRC of 600%
and an LRT of 180% will exhibit characteristics of: LRC star of 200% and LRT star of 60%. In some cases, this
may be enough to get the motor up to full speed, but mostly, as this is a constant voltage starter, the transition to
full voltage will occur at part speed resulting in a
virtual DOL type start. To step to full voltage, the
star connection is opened, effectively open 7 x FLC Full Voltage Stator Current

CURRENT (%Motor Full Load Current)

circuiting the motor, and the ends of the windings

TORQUE (% Motor Full Load Torque)

are then connected to the three phase supply in a 6 x FLC 2 x FLT

fashion to create a delta connection. This type of

5 x FLC
starter is an open transition starter and so the
switch to delta is accompanied by a very high torque 4 x FLC Full Voltage Star t Torque

and current transient. In most situations, there

3 x FLC 1 x FLT
would be less damage to the equipment and less
interference to the supply if a DOL starter was 2 x FLC
employed. The star delta is not easily converted to a
closed transition starter, and even the closed 1 x FLC
Sample Load Torque
transition Star Delta Starter still has the problem
that the start voltage can not be altered. If there is 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
insufficient torque available in star, then it will go to ROTOR SPEED (%Full Speed)
DOL. The star delta starter does get the regulations Fig.5 Typical Star-Delta Starting Curves
in some countries where there is a requirement for a
reduced voltage starter, but in reality, in many situations it results in more severe transients than DOL. The main
benefits of the Star Delta Starter are that it puts more money in the pockets of the switchgear supplier, and it is
only politically correct.

4] Soft Starter
7 x FLC
CURRENT (%Motor Full Load Current)

TORQUE (% Motor Full Load Torque)

Soft Starter is the most recommended and suitable 6 x FLC 2 x FLT
method for fixed speed AC motor starting.
Basically, Soft Starters are categorized on the basis 5 x FLC

of the technology used.

4 x FLC
Broadly, they are categorized into 2 sections
3 x FLC 1 x FLT
A] Reactor Soft Starter
2 x FLC

B] Electronic Soft Starter

1 x FLC
Sample Load Torque

Reactor Soft Starter 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
ROTOR SPEED (%Full Speed)

This method reduces the voltage, current and Fig.6

torque to the motor according to the reactor tap setting. It is possible to reduce the motor terminal voltage as
required by placing a primary reactor in series with the motor windings, for a period during starting. The use of a
reactor during starting results in an exceptionally low starting power factor. Reactors must be carefully designed
and applied since any saturation in the reactor will produce in-rush currents close to those seen during full
voltage starting. Reactor starting has one major advantage: the voltage to the motor is a function of the current
taken from the line. It can therefore be assumed that during acceleration, the motor voltage will rise as the line
current drops. This relationship results in greater accelerating energy at higher speeds and less severe
disturbances during the transition to full voltage. A typical torque speed curve by using a Soft Starter is shown in
figure 6.

6
The series reactor can be designed by two methods

1) Coreless Reactor
2) Iron Core reactor

Over the years, much of a research has been done on these two methods of core designing,
And Time and again it is proved that Air Core (coreless) type Series reactors are superior and are the right choice
while designing a series reactor for motor starter

Let us have a look at the advantages of Air Core Reactors :-

Air core Reactors are used where constant value of inductance is absolutely required. High Current air core
reactors are used with non magnetic materials.
As per the requirement of the client this can be manufactured in either Aluminum or Copper.

Air-core dry-type reactors in general

Air-core dry-type reactors are mainly employed in electric power transmission and distribution systems
as well as in electric power systems of electrical plants. They are installed to protect these systems and to
increase their efficiency. It is considered to be the best choice to design a Soft Starter for MV motors.
As a special application, air-core dry-type reactors will also be used in electrical test laboratories and research
institutions.

With the ongoing development of electrical power technology, especially through the increased use of
semiconductors in electric power systems, the requirements of power inductors have changed during the last
decades. The application spectrum for air-core dry-type reactors has been extended, caused by economic
advantages of the air-core reactor technology in comparison with iron-core reactors and by the benefits of
the linear characteristics of air-core reactors.

The utilization of new weatherproof insulation materials and advanced manufacturing technologies has
facilitated the use of air-core dry-type reactors up to the highest voltage and power levels.
Air-core dry-type reactors do not utilize an oil insulation system. They are environment friendly and
there are no fire hazard concerns. Furthermore, air-core dry-type reactors are essentially
maintenance-free.

Air Core Reactors: Electric air core reactors protect your plant and equipment from damaging power surges.
Reactors are designed as per International Standards and are suitable for indoor or outdoor use on systems
rated upto 800 kV. Each single or multi-layer cylindrically wound reactor has to be custom designed for a specific
application. Reactors can be used to:
Ÿ Reduce short circuit current levels
Ÿ Filter out dangerous harmonics, limit resonant system frequencies
Ÿ Limit in-rush currents/over voltages
Ÿ Reduce induced/secondary transients
Ÿ Balance currents in parallel circuits
Ÿ Compensate for capacitive voltages
Ÿ Protect Plant and Equipment From Damaging Power Transients
Ÿ Soft starting applications in 3 phase motors

Harmonic filter reactors

Harmonics are generated by non-linear components and loads in the power system. These elements are
characterized by a voltage drop which is not proportional to the current flow. In electrical power engineering, a
number of such non-linear loads exist in components and devices such as welding machines, electronic drive
systems or fluorescent lighting. You will also find them in household. For example, TV sets or computers.
Harmonic currents may have an adverse effect on different electrical components. These include transformers,
switches, capacitors, fuses and relays. The ill effects are increased losses and heating and/or excessive dielectric
stresses. If electric power systems are used for telecommunication purposes as well, harmonic currents may
affect the quality of the signal transmission. Electric utilities very often impose high charges when certain
maximum levels of harmonic distortion are exceeded.

7
Therefore harmonic currents have to be eliminated by filters. These harmonic filters, essentially consisting
of air core reactors and capacitors, are usually installed close to the source of harmonics in order to provide a
low impedance path for the harmonic currents. This is achieved by series connection of a filter air core
reactor with a capacitor bank, forming a filter circuit tuned to the harmonic frequency which needs to be
eliminated. If several harmonic frequencies need to be eliminated, a number of filters with different resonance
frequencies will be connected to the bus system, for instance the 3rd, 5th harmonic of the fundamental frequency
(50Hz or 60Hz) and the 7th.

If fine tuning of the filter is required, the filter reactor may be equipped with taps for inductance
adjustment.

Current limiting reactors

Current limiting reactors (a) are series connected to the transmission/distribution line or to the feeder or in
series with motor winding in order to limit the short-circuit power on the load side of the reactor. The reactor
limits the short-circuit current to a level which can be handled by the components installed in the electrical
system, such as breakers, switches or fuses. This represents the classical application of air-core
reactors. Due to the linear inductance-characteristics over the current range the full reactor impedance is
also maintained during system fault conditions.

Other special applications of current limiting reactors are:

• Load balancing reactors (b) for load sharing in parallel circuits
• Bus tie reactors (c) installed between two different bus systems
• Capacitor inrush current limiting or damping reactors (d)

Hence, looking at the above mentioned points, selecting an Air Core Reactor is a natural & right choice to build
a system for a correct motor starting method. We at Jayashree always use Air Core Reactors for designing a
Reactor Soft Starter. Heavy-duty design ensures long service life without maintenance no matter how tough
your operating environment is. Based on system and equipment analysis our experts will help you select the
right reactor and size it to your needs.

Iron Core Reactors

It is not necessary to talk about this technology in this document as this technology is fading out in motor
applications because of its overwhelming drawbacks such as:
• bulky and heavy construction
• Various problems such as saturation of iron core, noise and mechanical vibrations,
• eddy currents and iron losses,
• heating
• bigger size

8
Electronic Soft Starter

Electronic Soft Starter is also known as Solid State Reduced Voltage Starter.
The use of solid state Reduced Voltage Starting can provide a smooth stepless method of acceleration and
smoothly decelerating a squirrel cage induction motor. This type of starting method, when properly applied can
provide an efficient and reliable means of smoothly starting and stopping a motor and load. The use of solid-
state reduced voltage starting will perform, in most cases, more efficiently than field coupling, eddy current
drives and clutches. The stepless ramped acceleration and deceleration capabilities of these types of starter
reduces the inrush currents to the motor, eliminating transitional shocks to the load and reducing voltage flicker
on the distribution system. Electronic soft starter has other advantages related to the technology aspect. Some
of them are as follows:

• Precision Soft Starting

• Kick Start facility
• Soft Stopping
• Current Limited Starting (Range- 1.5 x FLC to 4.5 X FLC)
• Non standard Current Limit holds time (for very high inertia loads) Reduction in Peak Loads and
Maximum Demand during Starting
• Reduction in Sizing of Generator / Transformer
• Top of Ramp (full voltage) indication
• Facility to use with BYPASS Contactor
• Energy Saving at Partial Loads
• Improvement in Power Factor of Motor at Partial Loads
• Reduction in Reactive component KVAR at Partial Loads
• Reduces spikes impulses, surges on supply side during motor starting process•
• Reduced Wear & Tear on Electrical & Mechanical Components
• A Reduction in Maintenance Cost
• Motor Life is increased due to Lower motor temperature running
• Use with Slip Ring Motors with single stage Resistance in Rotor

We at Jayashree, manufacture Electronic Soft Starters with the technical collaboration with M/s Fairford
electronics (UK) since 1990.

9
REACTOR [HFSR] SOFT STARTER SPECIAL EDITION PAGES]

There are three basic methods for starting fixed speed 3 Ø AC motor,
1. Full Voltage Starting [ DOL]
2. Reduced Voltage Starting [ SOFT STATER]
3. Part Winding Starting [AUTOTRANSFORMER]

Soft Starter falls under the 2nd method.

Electrical Soft Starters can be designed by the following 2 different methods.

1. Series Resistance
3. Reduced Voltage Starting.
2. Series Reactor

Soft Starter is a very simple device. The main and ONLY objective of Soft Starter is to reduce the Motor Terminal
Voltage.
As per the current & torque requirements, the motor terminal voltage can be reduced. To achieve this reduction
of the motor terminal voltage, either of the above mentioned methods is used.

While designing a Soft Starter one must consider the following relation between motor and torque i.e.
% Reduction in terminal voltage = % Reduction in the square of the torque.

For example If the voltage is reduced to 50% of full voltage, the torque will be (.5) ² = .25, i.e. 25 % of the full
torque [while starting] Hence, while designing a Soft Starter, the torque requirements must be the prime factor
on which other parameters should be taken into consideration.

Always remember, there is no 'magic'. As per the rules of physics, the motor terminal voltage and torque
relation can never be changed.

Practically, the method of Series Resistance cannot be used as there are more drawbacks than benefits in using
the Series Resistance.
• The impedance of Series Resistance is fixed.
• The energy consumed by Series Resistance = I²R and is converted to heat is very high.

As a result, the Series Reactor type method is universally used while designing the Soft Starter.
The I²R losses are present in this type of starter also, but the value of R is negligible, typically in mΏ and hence
the Energy consumed by the reactor is very small.

The design of the Series Reactor should be such that it will introduce impedance in series with the motor winding,
which will reduce the voltage at the motor terminals to the desired value.

An important factor that should be considered while designing this series impedance is that the impedance itself
should not consume any energy; it should not generate heat, electrical and mechanical noise & vibrations.

REACTOR DESIGN:

The Series Reactor can be designed by two methods.

1) Coreless [ Air Core Reactors]
2) Iron Core Reactors.

Over the years, much of a research has been done on these two methods of core designing and time and again it
is proved that Air core [core less] type Series Reactors are superior and are the right choice while designing the
Series Reactor for Motor Starter.
While designing the Reactors, following parameters must be taken into the consideration.
1) Impedance of the Reactor coil [ to achieve the desired voltage at motor Terminals]
2) Maximum current through the Reactor coil [ to calculate the temp. rise]
3) Cross section of the conductor
4) Time for which the coil will be in circuit [ to calculate the total thermal effect ]
5) Total Temperature rise in the coil.
6) Coil insulation level.
7) Physical Dimension of the coil.

10
General comparison between two methods.

Parameter Coreless Iron Core Comments.

Copper Very high volume of Less copper is Manuf actures love to use iron
copper is required to required due to iron core in order to reduce the
achieve desired core. material cost.
impedance
Characteristics Perfectly linear Non linear A good design is always achieved
with the help of Air Core
Reactors.
Losses No Losses Iron Losses Iron Core Reactor is very less
ef ficient where as the Air Core
Reactors are highly ef ficient
Weight and Light weight, Bulky, heav y, Bigger Various problems are linked with
physical But costly in size , iron core Reactor, such as
Dimensions But economical. saturation of iron core, eddy
currents and iron losses and
heating.
Harmonics Not present. Air Core Present, due to Iron core can prove to be
Reactors are used as saturation of iron dangerous for the other
harmonics filters core equipments on the same line

Losses Negligible loss due to Air Power loss during Economically not good for the
Core starting due to Iron user.
Core

By looking at the above points, it is obvious that a businessman always prefers to use iron core as it is economical
to manufacture, but a good design engineer or a wise buyer will always prefer to have an Air Core Reactor.

While designing an Air Core [core less] Reactor for motor Soft Starter another design parameter is magnetic
flux. In air core Reactor, we at Jayashree Electron, place the three Reactor coils 120 º apart in space, which
virtually generates a neutral point at the center of these 3 reactors.

In Iron core Reactors, magnetic flux gets a path through the

Iron core present. This alternating flux causes eddy currents
& hysteresis losses in the Iron core and hence it is inefficient
media or method of starting. These losses get converted into
the heating of the iron core reactor and restrict the frequency
of consecutive starts. Hence the 'flux compensation 'in the
iron core Reactors has adverse effects for the motor starting
application. A carefully designed Iron Core, which has a much
bigger size than that of Air Core Reactor, is always used for
designing a transformer; hence iron core technology is
meant for transformer design as it is best suited for this
application. If an iron core reactor is to be designed for a
motor starting application, the size of the same will be in
multiples of that of air core, which nobody can opt for the
obvious reasons.

We at Jayashree Electron, carefully design the Reactor coils

placed 120 º in space. Typical arrangement of air core reactors, 120 º placement in space

The coils are vacuum impregnated and insulated with 'H' class insulation, with epoxy treatment for zero
maintenance.

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REFERENCES AND OTHER INFORMATION.

There are numerous references available for Air Core Reactors as well as iron core reactors. Air Core Reactor's
application band is very wide because of its superior performance and characteristics.

Another beauty of Air Core Reactors is that the impedance of the reactor is the function of the current passing
through the Reactor. Hence, while starting the motor, as the current starts reducing & the motor accelerates, the
voltage at motor terminal gradually increases linearly [ as Air Core Reactors have linear characteristics ] and as
the motor terminal voltage reaches its full voltage the reactors are bypassed. Thus, the motor starts smoothly
without any jerk.

If we take a look at various famous Books for motor control, it is always seen that reduced voltage Soft Starter is
essentially a open loop process, where there no feedback is required as all the parameters are predesigned and
calculated. As there is no feedback, it is obvious that there is no scope and NEED of amplification of any
parameter and also there is no need to complicate the simple process of series impedance.

There is a scope for dynamic impedance control by providing an auxiliary winding/reactor which will generate
magnetic flux in the opposite direction or in the same direction of the main reactor to increase or reduce the
effective series impedance in real time of the soft starter.If the reactor is so designed, it has to be tap less
reactor with an additional reactor control circuit along with power contactor which is same as that of bypass
contactor with a current control mechanism to change the flux of the control reactor in real-time. If this method
is used, a reactor can be designed with minimum information about the motor with no taps and it can be a
general solution for a range of motor size. But this solution works out to be too expensive i.e. multiple of the cost
of carefully designed open loop reactor giving the same result.

Only the buyer ends up paying way extra for the elements which the motor will never use. So a tapped reactor,
which is adjustable on site, is always a smart & economical choice. So whenever there are taps present to a
reactor, it is essentially an open loop predesigned reactor for the specific motor.

Some of the reference Books are

1) Electrical Control Systems in Industry C.S. SISKIND (1963)

ISBN 07-0-577463

2) Alternating Current Machines M.G. Say (1936)

ISBN 0273 36197X

3) Electric Motor Guide Edwin (1968)

4) Handbook of Electric Power Calculations ISBN 007-136298-3

And many more

All these Books indicate that:- reduce the voltage at the motor terminal to restrict the Current and then by the
linear characteristics of Air Core Reactor, smoothly accelerate the Motor.
The scientific name of this method is Series Reactor Soft Starter.

Many manufactures Misguide customers by selling the same product [Series Reactor - iron / air core] which is
actually a reduced voltage Soft Starter with different fancy names. Where as the product is as simple as it is
explained.

The beauty of this product is in the design of the Reactor coil as per the motor and load requirement to make a
perfect match.

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DESIGN YOUR OWN SOFT STARTER :

With Reactor coil, the current of a motor can be controlled up to an extent, where the Motor torque is slightly
greater than the load torque for the motor to accelerate. If one wishes to restrict the burden on the generator or
line side, a Capacitor Bank may prove to be useful to relax the momentary demand of the motor during starting.
These capacitors can be later utilized to control the power factor of the systems.

To design your Soft Starter, please supply us the following information via mail to hfsr@jayashree.co.in

Name :
Company Name :
E- Mail ID :
Contact Number :
Application :

1) Motor KW : *
2) Motor Voltage : V[ 415V/3.3KV/6.6KV/11KV]
3) Motor Full Load Current. : A
4) Motor efficiency : %
5) Motor RPM : RPM
6) Motor Starting Torque. : PU
7) Motor Starting Current : %FLC
8) Motor and Load GD ² : *
9) Motor Full Speed Torque : *
10) Motor T/S Curve
11) Load T/S Curve
12) Current Vs time Curve.

Send us as much possible data / information, so that we will be able to supply you with following
information.
1) Motor starting current with Soft Starter
2) Total starting time.
3) Soft Starter curves superimposed on motor curves.
4) Number of taps for various onsite settings.
5) Capacitor Bank Value.
6) Panel Dimensions.

Our advance software can predict and plot the various cases and can make you visualize how your motor
will perform with different load condition for different starting Ramp up time and current limits.

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