Electric Motor 5

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
Motor Starter Control Circuits
Note: The source of the technical material in this volume is the Professional Engineering Development Program (PEDP) of Engineering Services. Warning: The material contained in this document was developed for Saudi Aramco and is intended for the exclusive use of Saudi Aramcos employees. Any material contained in this document which is not already in the public domain may not be copied, reproduced, sold, given, or disclosed to third parties, or otherwise used in whole, or in part, without the written permission of the Vice President, Engineering Services, Saudi Aramco.
Chapter : Electrical File Reference: EEX21604
For additional information on this subject, contact W.A. Roussel on 874-1320
Electrical Motor Starter Control Circuits
CONTENTS
PAGE
CONTROL CIRCUIT COMPONENTS............................................................. 1 Pushbuttons.......................................................................................... 2 Selector Switches ................................................................................. 8 Position Versions...................................................................... 8 Circuit Breaker Control Switch .............................................. 10 Indicator Lights.................................................................................. 15 Full-Voltage............................................................................ 15 Transformer Type................................................................... 16 Push-to-Test Type .................................................................. 17 Control Relays ................................................................................... 18 Electromechanical .................................................................. 18 Solid-State .............................................................................. 20 Timer ...................................................................................... 20 Control Power Transformers (CPT)................................................... 21 Voltage Ratings ...................................................................... 21 Volt-Ampere Ratings.............................................................. 22 Fusing ..................................................................................... 23 Wiring ................................................................................................ 24 Types ...................................................................................... 24 Sizes ....................................................................................... 25 Contactor............................................................................................ 26 AC Coils ................................................................................. 27 DC Coils ................................................................................. 28 Circuit Breaker................................................................................... 29 Overload Relay .................................................................................. 32 MANUAL STARTER CONTROL CIRCUIT LOGIC..................................... 34 Control Logic Description.................................................................. 34
Toggling ................................................................................. 34 Pushbutton.............................................................................. 35 Mechanical Tripping .............................................................. 36 Reset ....................................................................................... 36 FULL VOLTAGE NON-REVERSING CONTROL CIRCUIT LOGIC .......... 38 Control Logic Description.................................................................. 38 Three-Point............................................................................. 38 Two-Point (Hand-Off-Auto)................................................... 41 Overload Relay Contact ......................................................... 43 Run/Stop Indicator (Pilot) Lights ........................................... 43 Medium Voltage Control Logic ......................................................... 44 Interposing Relay ................................................................... 44 CT Secondary Circuit ............................................................. 47 NEC Requirements ............................................................................ 48 Accidental Grounds ................................................................ 48 Voltage Limitations ................................................................ 50 FULL VOLTAGE REVERSING CONTROL CIRCUIT LOGIC.................... 51 Control Logic Description.................................................................. 51 Full-Speed Reversing (Small Motors).................................... 51 Stop Before Reversing (Medium Motors) .............................. 54 Time-Out Before Reversing (Large Motors) .......................... 55 Mechanical and Electrical Interlocks...................................... 56 REDUCED-VOLTAGE AUTOTRANSFORMER CONTROL CIRCUIT LOGIC ............................................................................................. 57 Control Logic Description.................................................................. 57 Mechanical and Electrical Interlocks...................................... 60 Transition Timer..................................................................... 60 Incomplete Sequence Timer ................................................... 61 Tap Selection.......................................................................... 61 REDUCED-VOLTAGE WYE-DELTA CONTROL CIRCUIT LOGIC.......... 62
Control Logic Description.................................................................. 63 Mechanical and Electrical Interlocks...................................... 64 Transition Timer..................................................................... 64 MULTI-SPEED CONTROL CIRCUIT LOGIC............................................... 65 Control Logic Description.................................................................. 65 Two-Speed Two-Winding Motors.......................................... 65 Two-Speed Single-Winding Motors....................................... 67 Mechanical and Electrical Interlocks...................................... 69 Multiple O/L Relays ............................................................... 69 TYPICAL ELECTRONIC (SOLID-STATE) CONTROL CIRCUIT LOGIC.. 70 Control Logic Description.................................................................. 73 Solid-State Interface Devices ................................................. 75 Current Feedback ................................................................... 75 Programmable Features .......................................................... 76 CIRCUIT BREAKER CONTROL CIRCUIT LOGIC ..................................... 77 Control Logic Description.................................................................. 79 Circuit Breaker Control Switch .............................................. 79 Closing Solenoid .................................................................... 80 Anti-Pumping Relay............................................................... 81 Trip Solenoid.......................................................................... 81 Relay Interface ....................................................................... 81 Indicator Lights ...................................................................... 82 Spring-Operated Mechanism.................................................. 82 GLOSSARY..................................................................................................... 83
LIST OF FIGURES Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Typical Motor Starter Schematic Showing Control Circuit as Ladder Diagram.......................................................................... 1 Normally Open Pushbutton............................................................ 2 Normally Closed Pushbutton ......................................................... 3 Types of Contact Assembly Blocks ............................................... 4 NEMA Type Designation (Reference NEMA Std. No. 2501991) .............................................................................................. 5 Ratings and Test Values for AC Control Circuit Contacts at 50 or 60 Hertz (Reference NEMA-ICS2-1988) ............................ 6 Ratings and Test Values for DC Control Circuit Contacts (Reference NEMA-ICS2-1988) ..................................................... 7 Position-Type Selector Switch ....................................................... 8 Schematic Diagram of Selector-Type Position Switch .................. 9
Figure 10. Typical Circuit Breaker Control Switch....................................... 10 Figure 11. Band, Row, and Stage Identification for a Typical Circuit Breaker Control Switch................................................................ 11 Figure 12. Example of Contact Operation for a One-Stage, Six-Contact Switch .......................................................................................... 12 Figure 13. One-Stage, Six-Contact Circuit Breaker Control Switch Using Slip/ Pull Contact Position................................................. 13 Figure 14. Continuous and Interrupting Current Ratings for Typical Circuit Breaker Control Switches.................................... 14 Figure 15. Lamp-Base Styles......................................................................... 15 Figure 16. Typical Voltage Ratings for Transformer-Type Indicating Lights ........................................................................................... 16 Figure 17. Push-To-Test Indicating Light ..................................................... 17 Figure 18. Typical Control Relays................................................................. 19 Figure 19. Typical Voltage Ratings for Control Power Transformer ............ 21 Figure 20. Typical Volt-Ampere Ratings for Control Power Transformer.... 22 Figure 21. Type of Controller Required per SAES-P-114............................. 24 Figure 22. Typical Operating Characteristics for AC Coils........................... 27 Figure 23. Typical Operating Characteristics for DC Coils........................... 29
Figure 24. Branch Circuit Short Circuit Protection (Control Circuit Conductors Contained Within Controller Enclosure) .................. 29 Figure 25. Branch Circuit Short Circuit Protection (Control Circuit Conductors Extending Beyond Controller Enclosure)................. 30 Figure 26. Overcurrent Protection ................................................................. 31 Figure 27. Example of Overload Relay Ratings ............................................ 33 Figure 28. Fractional Horsepower Toggle Switch Starter ............................. 34 Figure 29. Integral Horsepower Pushbutton Starter (Manual)....................... 35 Figure 30. Full Voltage Non-Reversing Motor Starter (Three-Point Control Circuit) ............................................................................ 39 Figure 31. Full Voltage Non-Reversing Motor Starter (Two-Point Control Circuit) ............................................................................ 42 Figure 32. Medium Voltage Starter With Interposing Relay and Current Transformers ................................................................................ 45 Figure 33. Example of Incorrect Control Circuit Wiring............................... 48 Figure 34. Example of Correct Control Circuit Wiring ................................. 49 Figure 35. Full Voltage, Full-Speed Reversing Motor Starter....................... 52 Figure 36. Full Voltage (Stop Before) Reversing Motor Starter ................... 54 Figure 37. Reduced-Voltage Autotransformer Motor Starter........................ 58 Figure 38. Equivalent Single-Phase Circuit for Autotransformer Motor Starter........................................................................................... 59 Figure 39. Reduced-Voltage Wye- Delta Motor Starter................................ 62 Figure 40. Multi-Speed Starter for Two-Speed Two-Winding Motor........... 66 Figure 41. Multi-Speed Starter for Two-Speed Single-Winding Motor........ 68 Figure 42. Typical Electronic Solid-State Motor Starter ............................... 71 Figure 43. Typical Manufacturer Ratings for Solid-State Starters ................ 72 Figure 44. Voltage Ramp Function for Solid-State Motor Starter................. 73 Figure 45. Torque Speed Characteristics for Current-Limit Function ........... 74 Figure 46. Standard Breaker Control Scheme (With DC Close, DC Trip and AC Spring Charging Motor) ................................................. 78
CONTROL CIRCUIT COMPONENTS Motor starter control circuits are often illustrated by means of a schematic ladder diagram similar to the one shown in Figure 1. With reference to this Figure, it is noted that components used for control circuits include pushbuttons, selector switches, indicating lights, control relays, control power transformers, auxiliary contacts, contactors, overload relays, circuit breakers or MCPs, and electrical wiring. The following sections of this Information Sheet describe the physical construction, optional variations, and mechanical and electrical ratings of these components.
Figure 1. Typical Motor Starter Schematic Showing Control Circuit as Ladder Diagram
Pushbuttons One component typically used in the control circuit of motor starters is the pushbutton. The pushbutton is used to energize the control circuit. A simple pushbutton is composed of a set of stationary contacts, a set of moving contacts, an operating plunger, a return spring, and a housing to hold the assembly together. Pushbuttons are basically one of two types: one with normally open contacts, and the other with normally closed contacts. For the normally open pushbutton (Figure 2), the operating plunger is held up by a return spring. This spring holds the moving contacts away from the stationary contacts, and it, thereby, keeps the control circuit open and de-energized. Depressing the plunger causes the moving contacts to engage the stationary contacts, thus closing the circuit. Normally open pushbuttons are typically used to start a process.
Figure 2. Normally Open Pushbutton
In the normally closed pushbutton (Figure 3), the design of the contacts is opposite to that of the normally open pushbutton. For this type, the contacts open, and the process stops when the plunger is depressed. As a result of the internal tension caused by the return spring, the action of both the normally open and normally closed pushbuttons is momentary. When the operators finger is removed from the pushbutton, it returns to its original state.
Figure 3. Normally Closed Pushbutton
The pushbuttons, which are illustrated in Figures 2 and 3, have only one set of contacts. However, pushbuttons can accommodate multiple sets of contacts, both normally open and normally closed. Some manufacturers construct multiple-contact pushbuttons as a single unified assembly with the desired number of contacts included. Other manufacturers offer the pushbutton actuators and the current carrying contacts as separate assemblies that can be mixed and matched to suit the requirements of the application. For pushbuttons where the contacts are offered as separate block assemblies, as many as eight blocks (circuits) can be mounted side by side or stacked in tandem and operated from one pushbutton. The contact assemblies are generally mounted in a transparent housing that allows visible inspection of contact condition and status. Contact assemblies are typically available in a variety of functional styles. Figure 4 lists some of the common functional styles offered by manufacturers.
Figure 4. Types of Contact Assembly Blocks
To address specific application needs of selected pushbuttons, accessories are available for use with the pushbuttons. Some of the accessories available for use with pushbuttons include a padlockable cover to allow locking the pushbutton, protective shrouds to prevent inadvertent operation, and rubber boots to provide additional sealing of the pushbutton against dust and water.
In addition to other considerations, pushbuttons are designed and manufactured to meet various environmental requirements. They are considered to be dust tight, water tight, and/or oil tight if, when properly mounted in a suitable enclosure, the assembly meets the applicable design requirements given in the standards used to qualify enclosures for electrical equipment (NEMA Standards Publication No. ICS 6, and ICS 250). In accordance with these standards, pushbuttons are identified by a type number. Figure 5 lists some of the more common type designation numbers applied to pushbuttons and the environmental conditions they protect against.
Figure 5. NEMA Type Designation (Reference NEMA Std. No. 250-1991)
With regard to current carrying capability, pushbuttons are identified as being either standardduty or heavy-duty. In accordance with NEMA standards, standard-duty pushbuttons have contact rating designations of B600, B300, B150, P600, or P150 as shown in Figure 6 for alternating current and Figure 7 for direct current. Heavy-duty pushbuttons have contact rating designations of A600, A300, A150, N600, N300, or N150 as shown in Figure 6 for alternating current and in Figure 7 for direct current.
Figure 6. Ratings and Test Values for AC Control Circuit Contacts at 50 or 60 Hertz
(Reference NEMA-ICS2-1988)
Figure 7. Ratings and Test Values for DC Control Circuit Contacts (Reference NEMA-ICS21988)
Selector Switches Position Versions A position-type selector switch (Figure 8) is similar to a pushbutton in the sense that it serves the same function, which is to energize a control circuit. However, unlike the momentary action of the pushbutton, the position-type selector switch, once set, maintains its contact engagement without the need of a seal-in interlock.
Figure 8. Position-Type Selector Switch Position-type selector switches come in two functional styles; two position rotary switches and three-position rotary switches. The two-position switch has moving contacts and stationary contacts that allow two switch positions, one off position and one selected position. The three-position switch has moving contacts and stationary contacts that allow three switch positions, one off position and two separately selected positions. These switches are illustrated schematically in Figure 9.
Figure 9. Schematic Diagram of Selector-Type Position Switch Like the pushbutton switch, the selector-type position switch is offered by some manufacturers as a two-part assembly. One part is the rotary handle, and the other part is a separate contact assembly block. Each contact block contains one set of either normally-open or normally-closed contacts. The contact blocks listed in Figure 4 for pushbutton switches are also available for position selector switches. As many as four contact block assemblies can be mounted side-by-side or in tandem, and then operated from one rotating handle. Selector-type position switches are also designed to meet environmental requirements. They are identified by the same type number designation, and must comply with the same standards (NEMA Standards Publication No. ICS 6, and ICS 250), as pushbutton switches . The examples of type designations listed in Figure 5 for pushbutton switches also apply to position selector switches.
Finally, the current-carrying capability of contacts for selector-type position switches are rated using the same method as used for pushbutton switches. The selector switches are identified as either standard-duty or heavy-duty. In accordance with NEMA standards, standard-duty selector switches have contact rating designations of B600, B300, B150, P600, or P150 as shown in Figure 6 for alternating current and in Figure 7 for direct current. Heavy-duty selector switches have contact rating designations of A600, A300, A150, N600, N300, or N150, as shown in Figure 6, for alternating current and Figure 7 for direct current. Circuit Breaker Control Switch A circuit breaker control switch is a rotary power switch designed for heavy duty control systems. Built with a spring operating action that returns the switch to its original or neutral position, it is well suited for circuit breaker control where momentary contact is required. A typical circuit breaker control switch (refer to Figure 10) consists essentially of an operating handle, face plate, control housing, frame contact assembly and rotor contact assembly. The frame contact assembly and rotor contact assembly form a contact stage. Switches are identified by the number of stages that they contain, and may be built with from one to eight stages mounted on the steel operating shaft.
Figure 10. Typical Circuit Breaker Control Switch
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Each contact stage of a circuit breaker control switch has a minimum of two, and a maximum of up to twelve rotary positions (refer to Figure 11). The frame contacts are positioned around the frame at 30o intervals, and they are identified in the same manner as the numbers on a clock. At every position location on the frame, there are two contacts in line (a set) per stage. The roller contact assembly is made up of from one to six rollers (depending on the requirements for the specific switch). As the switch is operated, the roller contacts internally bridge the adjacent sets of stationary contacts, completing their connected circuits.
Figure 11. Band, Row, and Stage Identification for a Typical Circuit Breaker Control Switch
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For purposes of instruction and documentation, the contacts of this type of switch are identified by combination of bands and rows. Viewing the switch shown in Figure 11 from the handle end, a terminal row is identified as the row of contacts at one of the clock positions. Thus, for a given switch, there are twelve possible rows, which are identified as rows one through twelve and are located in the same position as the hours on a clock. Viewing the switch in Figure 11 from the side, the individual bands are identified as the set of contacts located in one clockface (plane). The band nearest the handle end is band A, the second band is band B, etc. Bands A and B constitute stage one, and bands C and D constitute stage two. To complete a circuit, the roller contact bridges a set of stationary contacts in the same row. As an example, completing the circuit between the contacts located in row 12 of bands A and B is noted as (A12-B12). By varying the combination of contact rows, bands, and stages, the number of contact arrangements that are possible from a circuit breaker control switch is almost unlimited. To assure that users are aware of the contact arrangements for a given switch, manufacturers use a schematic diagram and table to illustrate the operation of each switch. Figure 12 shows one example of the type of diagram and table used to convey this information. In this case, the switch is assembled with six rows of contacts at clock positions 11, 12, 1, 5, 6 & 7, and two bands (one stage). As illustrated by the diagram and noted in the accompanying table, one set of contacts is closed as the switch is moved through each of its six functioning clock positions.
Figure 12. Example of Contact Operation for a One-Stage, Six-Contact Switch
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In addition to rotary motion, circuit breaker control switches are typically provided with a lateral movement (push-pull) of the handle and shaft. This position is referred to as the slip or pull contact, and it is used for trip lockout. Figure 13 gives an example of a circuit breaker control switch that has this feature, and it shows the relevant wiring diagram for the circuit breaker.
Figure 13. One-Stage, Six-Contact Circuit Breaker Control Switch Using Slip/ Pull Contact Position
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The circuit breaker control switch is a very durable switch designed for rugged duty and capable of carrying and switching higher currents than the position-type selector switch. As an example, at 240 volts the heavy-duty position selector switch is typically capable of interrupting a circuit with 3 amperes, while the circuit breaker switch, at the same voltage, will interrupt 20 amperes. The range of continuous and interrupting current ratings for typical circuit breaker control switches is shown in Figure 14.
Figure 14. Continuous and Interrupting Current Ratings for Typical Circuit Breaker Control Switches
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Indicator Lights Indicating lamps are another component used in motor starter control circuits. Their function is a relatively simple but important one, which is to report the status of the control circuit and, as a result, the status of the equipment controlled. A variety of colors are used for the lens of the indicating lights to report or warn of various circuit conditions. Colors typically offered by manufacturers include red, green, blue, amber, white and clear. The most commonly used types of indicating lights include the full-voltage, transformer and push-to-test types. Full-Voltage In a full-voltage indicating light, the lamp operates at the full voltage of the control circuit. This voltage is applied directly to the terminals at the body of the light. For reasons of safety, the maximum voltage rating for this type of indicating light is 120 volts AC/DC. Other voltage ratings available for this style of light are 6, 12, 24, 28/32, and 48 volts AC/DC. The full-voltage indicating light is manufactured in two lamp-base styles: the candelabra style and the bayonet style. Figure 15 shows an illustration of the two lamp-base styles.
Figure 15. Lamp-Base Styles
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Transformer Type The transformer type of indicating light is essentially designed for use with circuit voltages higher than 120 volts. The unique feature for this type of indicating light is that it comes with a built-in or attached transformer that connects to the higher voltage circuit and steps the voltage down to a safe level for the lamp. Although intended primarily for use with circuit voltages above 120 volts, the transformer-type indicating light is also available in lower voltage ratings. Figure 16 lists the voltage ratings typically available for this style of light. Similar to the full-voltage style, the transformer indicating light is available in both the candelabra and bayonet lamp-base styles.
Figure 16. Typical Voltage Ratings for Transformer-Type Indicating Lights
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Push-to-Test Type The push-to-test type indicating light has the unique feature of allowing its lamp to be tested for satisfactory operation without disturbing the control circuit that it is monitoring. This test is accomplished with the use of a pushbutton that is provided as part of the indicating light assembly. The schematic diagram shown in Figure 17 illustrates how the test is accomplished without disturbing or altering the control circuit. As seen in Figure 17, operating the pushbutton for the indicating light completes the circuit from one side of the supply voltage, through the light, to the other supply line. In this manner, relay and pilot contacts are left undisturbed, while the lamp is energized and de-energized for verification of operation.
Figure 17. Push-To-Test Indicating Light
The push-to test light is available as both a transformer style indicating light and also a fullvoltage style indicating light. For the transformer style, it is offered in voltage ratings of 120/110, 240/220 and 480 volts. In the full voltage style, it is offered as a bayonet base lamp or LED (Light Emitting Diode) at voltage ratings of 12, 24 and 120 volts AC/DC.
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Control Relays A control relay is a component that is used in a motor starters control circuit to interface between a pilot device and the circuit that the pilot device controls. In effect, the control relay allows the pilot device to control a current that is too large for the contacts of the pilot device. Pilot devices used in motor controls typically monitor parameters such as time, pressure, liquid level, and heat. When the pilot device activates, it allows the control relay to pickup, which in turn allows a higher current control circuit to be energized. For some cases, more than one pilot device may have to be activated before a control circuit is permitted (through the control relay) to be activated. Several types of control relays are available for use in control circuits. Some common types include electromechanical, solid-state and timer relays. Most of these relays are available in either 4- or 6-pole configuration. Many types can be easily converted to 8- or 10-poles by adding an additional 4-pole unit. Contacts are convertible between normally open (NO) and normally closed (NC). Electromechanical One type of control relay is the electromechanical type (Figure 18a). This relay uses an electromagnet to move the output contacts from open to closed and closed to open. Relays of this type are referred to as alternating current relays, if designed for actuation from an AC source, or direct-current relays, if designed for DC operation. The contact construction for electromechanical relays may be convertible, fixed or universal. Convertible construction allows contacts to be changed in the field from normally open to normally closed and vice versa. Fixed construction means contacts are either normally open or normally closed and cannot be changed. Universal construction provides both a normally open and a normally closed set of contacts on each pole of the relay, but only one or the other may be used. The classes of electromagnetic control relays are designated in terms of their contact ratings by means of letters and numerals. The letter indicates the rating of the contacts in accordance with Figure 6 (Ratings and Test Values for AC Control Circuit Contacts at 50 or 60 Hertz) or Figure 7 (Ratings and Test Values for DC Control Circuit Contacts), and the number indicates the maximum voltage rating of 600, 300 or 150. As an example, a relay designated A600 is a relay which has class A600 contacts (per Figure 6), is suitable for use at alternating-current voltages through 600 volts, and has a thermal continuous current rating of 10 amperes.
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Figure 18. Typical Control Relays
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Solid-State The solid-state control relay (Figure 18b) performs the same function as the electromechanical control relay; that is, it controls the flow of current in a control circuit in response to a lower level signal from a pilot device. However, the method used by the solidstate device to close and open the current flow is very different. The solid-state relay uses semiconducting devices (i.e. SCRs, transistors) instead of open-air contacts for the switching operation. The solid-state relay is constructed with a totally encapsulated body that provides protection of internal components against shock, vibration, dirt, and other environmental hazards. Because the relay is constructed of solid-state devices, there are no moving components to wear, thus yielding a longer service life than the electromechanical type, provided the ratings of the solid-state relay are not exceeded. The solid-state relay requires two voltages to be applied to it for operation of its solid-state contacts. One voltage is a nominal fixed line voltage (e.g. 120/110 VAC), and the other voltage is an input voltage modulated by the pilot device. For typical solid-state relays, the input voltage may range from 5 volts up to 120 volts AC with respective currents of only a few milliamperes. Application of the two voltages will in turn cause the solid-state contacts (either normally open or normally closed) to operate. A typical alternating current rating for a solid-state contact is 132 VAC, 2 amperes continuous and 5 amperes inrush current. Timer The timer control relay is available as either an electromechanical or solid-state type relay. The relay can be purchased with normally open contacts, normally closed contacts, or a combination of the two types. This type of relay functions as described above for either the electromechanical or solid-state type, except that it has a built-in timing circuit that delays the operation of the relay contacts. Timing relays are offered with two types of timing modes. One is for on-delay application and the other is for off-delay application. For the on-delay application, once the relay is energized to operate, it goes through its preset timing cycle before it operates its contacts. The de-energizing operation for the on-delay type has no time delay cycle. For the off-delay application, contact operation on energizing the relay is normal (no time delay); however, on de-energizing, the relay goes through its preset timing cycle before the contacts are operated. Time delay cycles for this type of relay are available in ranges from less than one second to five minutes. Current and voltage ratings are the same as for electromechanical and solidstate relays without time delay.
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Control Power Transformers (CPT) The voltage needed to operate the control circuit is normally taken from the main power circuit of the motor starter, as shown in Figure 1. To connect the power circuit to the control circuit, a control power transformer (CPT) is used. The transformer is a standard single-phase design consisting of two windings connected by a common core. Power is transformed from the primary to the secondary winding in accordance with the principles of magnetic induction. The control power transformer is selected and sized according to the voltage rating and voltampere capacity of its windings. Voltage Ratings Control circuits are designed to operate at relatively low voltage levels (110 to 120 volts AC) in order to provide safety for operating personnel. Motor starter power circuits, however, operate typically at one of several higher voltage levels. For this reason, control power transformers are available in a variety of voltage ratings and voltage ratio combinations. When sizing a control transformer to the power circuit, the winding voltage ratings must be selected to match the voltages of the control and power circuits. More commonly, the transformer is sized and provided by the manufacturer as an integral part of the controller. Figure 19 lists the voltage ratings for typical control power transformers available from one manufacturer.
Figure 19. Typical Voltage Ratings for Control Power Transformer
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Volt-Ampere Ratings In addition to the voltage rating of the windings, the control power transformer is also rated in accordance with it volt-ampere capacity. With the voltage rating of the windings identified, the volt-ampere rating determines the maximum current that the winding can carry without overheating. As an example, for a transformer rated at 500 VA with a primary winding of 480 volts and a secondary winding of 120 volts, it is determined that the maximum safe primary current is 500 VA/ 480 V = 1.04 amperes. The maximum safe secondary current is 500 VA/ 120 V = 4.2 amperes. Typical volt-ampere ratings available for control power transformers range from 50 VA to 2000 VA. Similar to the voltage rating of the windings, the volt-ampere rating for the transformer is commonly determined by the manufacturer when the transformer is supplied as part of the controller. Figure 20 lists the volt-ampere ratings of control power transformer with NEMA sized contactors 00 through 6 as typically provided by one manufacturer.
Figure 20. Typical Volt-Ampere Ratings for Control Power Transformer
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Fusing With reference to Figure 1, control power transformers are typically provided with two fuses in the primary winding circuit and one fuse in the ungrounded leg of the secondary winding circuit. The fuses are normally contained in a three-pole fuse block mounted on top of the transformer. The physical dimensions of the primary and secondary fuses are intentionally made different to prevent installing them in the wrong pole of the fuse block. The single fuse located in the ungrounded leg of the secondary winding circuit basically provides overcurrent protection for the control circuit conductors and components, but it must also provide overcurrent protection for the transformer secondary. In accordance with the National Electric Code, this fuse must meet the requirements of NEC Article 240 for protection of the control circuit conductors, and it must also meet the requirements of NEC Article 450 for protection of the transformer secondary. The two fuses located in the primary winding circuit provide overcurrent protection specifically for the transformer. Required sizing for these fuses must be in accordance with NEC Article 450. In general, for transformers rated 600 volts, nominal or less the protection must comply with one of the two following requirements: Transformer shall be protected by a device on the primary side rated or set at not more than 125 percent of the rated primary current of the transformer. Transformers with an overcurrent device on the secondary side rated or set at not more than 125% of rated secondary current shall not be required to have an individual overcurrent device on the primary side if the primary feeder overcurrent device is rated or set at a current value not more than 250% of the rated primary current of the transformer.
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Wiring Types The types of control wiring used for combination controllers are determined and provided by the manufacturer as an integral part of the combination controllers. The wiring types used are selected in accordance with customer, NEMA and NEC standards. Figure 21 shows the types of controllers that Saudi Aramco requires. Referring to this figure helps to identify the combination controllers used by Saudi Aramco that have their wiring provided as an integral part of the controller. With reference to Figure 21, it is noted that combination controllers are required for induction motors rated 600 volts and below and greater than 1 to 100 horsepower. For induction and synchronous motors rated 4000 volts and above and 1500 horsepower or less, class E2 combination controllers are an approved selection. The wiring for these controllers is provided by the manufacturer as an integral part of the controllers.
Figure 21. Type of Controller Required per SAES-P-114
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With regard to the type of control wiring used for low-voltage controllers, 16-SAMSS-503 specifies that all wiring used for motor controllers rated 600 volts and below must be stranded electrical grade copper with 600-volt insulation. With regard to the type of control wiring used for medium voltage controllers, 16-SAMSS506 specifies that conductors must be stranded copper, rated 600-volt NEC Type SIS or THHN. Each wire must be identified with a thermoplastic, slip-on wire marker with permanently printed characters (snap-on and adhesive type markers are prohibited). Sizes With regard to the size of control wire used in combination starters, the manufacturer selects the size (as was done in selecting wire type) in accordance with customer specifications, and NEMA and NEC standards. Saudi Aramco requirements for control wiring for low-voltage controllers are specified in 16SAMSS-503. The requirement per this specification is that all conductors must be a minimum size of 2.5 square mm (14 AWG). Saudi Aramco requirements for control wiring for medium voltage controllers are specified in 16-SAMSS-506. The requirement per this specification is the same as for low-voltage controllers, which is that all conductors be a minimum size of 2.5 square mm (14 AWG).
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Contactor In a motor starter circuit, the contactor is normally considered to be part of the power circuit because it makes and breaks the circuit carrying the motor current. However, the contactor is unique in the sense that a portion of its elements are connected in the power circuit (the main motor current contacts), while the remainder of the elements are connected in the control circuit (coil and auxiliary contacts). With regard to the contactor elements contained in the control circuit, Figure 1 (Typical Motor Starter Schematic) shows the connection of the contactor coil (labeled M) and the auxiliary contacts (labeled Ma and Mb) for a full-voltage non-reversing starter. The main function of the contactor coil is to magnetically open and close the main contacts, also labeled M, thus controlling the operation of the motor. The coil is physically mounted on a core that is constructed of thin, individual metal laminations riveted together. The core and coil form an electromagnet. Energizing the coil causes an armature (mechanically linked to the main contacts) to operate, thus opening and closing the main contacts. Contactors are available with either AC or DC voltage coils. The auxiliary contacts associated with the main contactor are identified with the capital letter M and the subscripts a and b (Ma, Mb). The auxiliaries may be contained within the contactor assembly, or they may be provided as an attachment accessory. They are commonly provided in sets of two with one normally open contact and one normally closed contact. The contacts are designed to interlock the main contactor with the control circuit and are thus designed to carry no more than 10 amperes continuously.
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AC Coils Contactors with alternating-current coils are available in a wide range of coil voltage ratings (24 volts AC to 600 volts AC). In accordance with NEMA Standard ICS 2-110, alternatingcurrent operated contactors must withstand 110 percent of their rated voltage continuously without injury to the operating coil and must close successfully at 85 percent of their rated voltage. Figure 22 lists the typical operating characteristics of AC coils for contactors of NEMA size 00 through 6.
Figure 22. Typical Operating Characteristics for AC Coils
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DC Coils Contactors are also available with coils that operate on direct current. Typical voltage ratings for these coils range from 24 to 250 volts DC. In accordance with NEMA Standard ICS 2110, direct-current operated contactors must withstand 110 percent of their rated voltage continuously without injury to the operating coil and must close successfully at 80 percent of their rated voltage. Figure 23 lists the typical operating characteristics of DC coils for contactors of NEMA size 00 through 6.
Figure 23. Typical Operating Characteristics for DC Coils
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Circuit Breaker As described in the preceding Module EEX216.01 Motor Starter Components and Standards, circuit breakers (instantaneous trip and inverse time) are normally used to provide short circuit and ground fault protection for the power circuit of the motor. Circuit breakers are ordinarily not considered part of the control circuit for the motor starter. However, under certain conditions, the circuit breaker that provides the motor branch circuit short circuit protection, may also be used to protect the control circuit conductors. The conditions under which this is allowed are given in NEMA Standard ICS 1-112.61. In general, control-circuit conductors that do not extend beyond the motor controller enclosure are considered protected by the circuit breaker providing branch circuit short circuit protection if the rating or trip setting of the breaker does not exceed the values shown in Figure 24.
Figure 24. Branch Circuit Short Circuit Protection (Control Circuit Conductors Contained Within Controller Enclosure)
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When control circuit conductors extend beyond the motor controller enclosure, then they are considered to be protected by the circuit breaker providing branch circuit short circuit protection if the rating or trip setting of the breaker does not exceed the values shown in Figure 25.
Figure 25. Branch Circuit Short Circuit Protection (Control Circuit Conductors Extending Beyond Controller Enclosure)
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For both cases above (conductors contained within the enclosure, and conductors extending beyond the enclosure), when the rating or trip setting of the circuit breaker exceeds the values given in the relevant figure (Figure 24 or Figure 25), the control circuit must be protected by a supplementary overcurrent device (e.g. fuses) with a rating not to exceed the values given in Figure 26.
Figure 26. Overcurrent Protection
In accordance with 16-SAMSS-503, ARAMCO requires each low-voltage combination motor controller to have a control power transformer (CPT) to supply the control circuit. The CPT must be provided with primary current-limiting fuses and a secondary general purpose fuse.
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Overload Relay The overload relay is another component in the motor starter that is connected in both the power circuit of the motor and the control circuit of the motor starter. As illustrated in Figure 1, the thermal sensing elements of the overload relay for low-voltage starters are connected directly in series with the conductors that carry the current to the motor (for medium voltage starters, the overload relays are connected through current transformers). In this manner, the motors load current is monitored to determine if the level of current exceeds the rating of the thermal elements. In accordance with the time-current characteristics for the relay, an overcurrent continuing for a predetermined time will cause the relay contacts to operate. Overload relays are available from manufacturers in a three-pole configuration, with three thermal elements (one in each pole), or as a single-pole relay with one thermal element. Both configurations are provided with one normally closed contact that opens when an overload condition is detected. For three-phase motors, one three-pole relay or three individual singlepole relays can be used to provide the overload protection. The advantage of using three single-pole relays is that this arrangement provides good protection against a single-phase condition for the three-phase motor. On the other hand, three-pole overload relays provide only limited protection against a single-phase condition. The normally closed relay contact (identified as OL in Figure 1), is connected in the control circuit of the motor starter. When mechanically operated by the thermal sensors, in response to a timed overcurrent, the contact interrupts the current flow to the contactor coil. This action in turn opens the contactor and shuts down the motor. The contact of the overload relay which operates in the control circuit is designed, manufactured, and rated in accordance with the NEMA ICS-2 ratings shown above in Figure 6 (Ratings and Test Values for AC Control Circuit Contacts at 50 or 60 Hertz), and in Figure 7 (Ratings and Test Values for DC Control Circuit Contacts). The current rating of an overload relay is expressed in amperes at an ambient temperature of 40oC. Ratings for overload relays are given as a range of motor full-load amperes.
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As an example of overload relay ratings, Figure 27 lists a few of the current ratings offered by one manufacturer for one type of overload relay for low-voltage starters. Reviewing the individual ratings shown in this figure gives a good indication of the range of currents that each relay is capable of handling.
Figure 27. Example of Overload Relay Ratings
The actual level of current that the overload relay will operate at is determined by the rating of its thermal elements. The thermal elements (sometimes called heaters) have a rating that is similar to the overload relay in the sense that it is also based on the motor full-load current. But it is a separate rating with a much smaller range in amperes. The rating of the selected thermal elements, when mounted in a compatible overcurrent relay, determines the timecurrent operation of the relay. With respect to time of operation, overload relays with inverse time-current characteristics are designated by a NEMA specified class number (10, 15, 20 or 30). The class number indicates the maximum time in seconds required for the relay to operate when carrying 600 percent of its current rating. The rating and selection of thermal elements, together with a description of relay time classes are described in detail in Module EEX 216.04 Selecting Low-Voltage Motor Starters.
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MANUAL STARTER CONTROL CIRCUIT LOGIC Control Logic Description Manual motor starters are used where only on-off operation is required for small, single-phase or three-phase motors, and full voltage across-the-line starting is acceptable. General application includes control of small AC and DC motors where remote control is not required, where the operator is in attendance at the driven load and needs control at that location, and where conditions eliminate any hazard due to sudden restarting of motors upon restoration of power. Size of motors controlled with manual starters are typically limited to 10 horsepower or less. Toggling The simplest type of manual starter is a 1-, 2- or 3-pole toggle operated switch used for infrequent starting and stopping of small motors. The toggle operated switch consists of a basic snap-action mechanism that connects the motor to the line in the on position and disconnects the motor when in the off position. The toggle switch has a third position called the trip position, which is the position the handle is left in when the thermal device trips the starter. When in the trip position, the handle must be manually moved to the off position before it can be switched to the on position. When a toggle operated switch is mounted inside a NEMA type enclosure, the toggle handle that operates the contact assembly protrudes through the enclosure cover. To provide running overload protection, the manually operated switch contains a thermal device to open the circuit on overloads (Figure 28). The thermal unit is typically a plug-in element that is keyed for proper positioning in the switch. Elements are typically rated to provide 115% to 125% protection with the rating marked directly on the element.
Figure 28. Fractional Horsepower Toggle Switch Starter
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Pushbutton Manual starters can also be provided with pushbuttons for operation of the starter. For this case, the pushbuttons are mechanically coupled to the contact assembly as illustrated in Figure 29. The pushbutton type starter has a start pushbutton to connect the motor to the line, an off pushbutton to disconnect the motor, and a pop-out trip indicator that serves as a reset pushbutton to reset the starter following a trip operation by the thermal device.
Figure 29. Integral Horsepower Pushbutton Starter (Manual)
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Mechanical Tripping Tripping or opening of the manual type starter is accomplished by one of two methods. The first method is to operate the toggle handle (or pushbutton) manually. The toggle handle (or pushbutton) is mechanically linked to the mechanism that operates the contacts. To assure that the contacts move with sufficient velocity to reliably make and break their rated current, the mechanism is designed to provide a very quick snap-action operation. Manually operating the toggle handle (or pushbutton) is generally intended for opening the motor circuit under normal conditions with no overcurrent. The second method of tripping the manual starter is accomplished automatically by the thermal device when an overcurrent exists for a period of time exceeding the time-current characteristics of the device. The thermal device is mechanically linked to the contact operating mechanism in a manner similar to the toggle handle. When an overcurrent is determined to exist for a longer than allowed period, the thermal device mechanically operates the contact opening mechanism in the same manner as the toggle handle. Reset The thermal device provides running overload protection for the manually toggle operated (or pushbutton operated) starter by opening the circuit on overloads. When the thermal device trips the starter, the starter toggle handle is left in the trip position. The toggle handle (or pushbutton) must be then manually reset from the trip position to the Off position, after cooling, before it can be physically operated to the On or closed position. This resetting procedure is a safety precaution that is built into the starter switch and is known as a trip free design. The trip free design of the starter is accomplished through the construction of the contact mechanism and its method of coupling to the thermal device. In addition to requiring the toggle handle to be reset to Off after overload tripping, the trip free design prevents holding the switch closed against a sustained motor overload. Although manual starters are equipped with overload protection, they do not have the form of protection known as low-voltage or under-voltage protection. As a result, the motor is not protected against overheating that can be caused by low-voltage operation. In addition to this lack of protection, the further problem exists that a power failure or other loss of voltage to the motor circuit will cause the motor to stop, but not be disconnected from the supply circuit. For this condition, the starter contacts remain closed and the motor will restart immediately on restoration of power. Such an effect can be hazardous when machine operators or maintenance personnel who are working on the motor are taken by surprise on the sudden restoration of power.
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The above information on manual starters is provided for the general knowledge of the participant. Saudi Aramco standards do not permit use of manual starters. In accordance with 16-SAMSS-503, controller specifications for motors rated 0.75 kW (1.0 hp) or less allow using only a molded case circuit breaker with three-pole thermal-magnetic trip unit, or a combination controller. For motors greater than 0.75 kW (1.0 hp) to 75 kW (100 hp) 16SAMSS-503 requires use only of a combination controller with either a three-pole thermalmagnetic molded case circuit breaker, a three-pole overload device and a three- pole magnetic-trip only molded case circuit breaker, or a three-pole overload device and a threepole motor circuit protector (MCP).
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FULL VOLTAGE NON-REVERSING CONTROL CIRCUIT LOGIC The full voltage non-reversing motor starter is relatively simple in construction, easy to maintain, and the least expensive of all AC motor starters. This type of starter is used for control of three-phase motors where full-voltage starting is acceptable and where the motor is to start up and run in one direction only. The control circuit used for control of the full voltage non-reversing starter is normally one of two types, either the three point control circuit (Figure 30), or the two point control circuit (Figure 31). This Information Sheet describes the logic and requirements for these circuits as used in both low- and medium-voltage starters.
Control Logic Description Three-Point Figure 30 shows a three-point (or three-wire) control scheme with the control wiring tapped off the line-side terminals of the starter. Since the control circuit derives its current supply from the same branch circuit that supplies the power to the motor, it is also disconnected when the disconnecting means ahead of the starter is opened. The three-point circuit gets its name from the fact that this arrangement requires three points for connection of the pushbuttons to the starter.
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Figure 30. Full Voltage Non-Reversing Motor Starter (Three-Point Control Circuit)
To trace the operation of the three-point control circuit, it is important to first note two items of information regarding the components. First, the pushbuttons are the momentary type. That means that the pushbuttons open or close for as long as they are pushed. Once released, the pushbuttons return to their original state (either normally open or normally closed). The second item that is important to note is that all components are shown in the diagram in their de-energized state.
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With these two items of information noted, the operation of the circuit can be described beginning with the closing of the start button. When the start button is pushed, the circuit to the starters contactor coil is completed, and the main contacts of the starter close allowing current to flow to the motor. At the same instant, the red indicating light is turned on, and the auxiliary contacts Ma and Mb operate. Contact Ma, which is normally open, changes to the closed position completing the circuit around the start button so that the circuit to the coil is maintained when the button is released. Contact Ma is referred to as the seal-in contact, as the control circuit is now sealed-in until the stop button is operated. Auxiliary contact Mb, which is normally closed, opens when operated, turning off the green indicating light. Under these conditions, the motor is connected directly across the line, and starts at full voltage. When it is desired to stop the motor, momentary depression of the stop button breaks the control circuit, releasing the starter contacts, which removes the power to the motor. As before, the auxiliary contacts Ma and Mb operate in unison with the main contactor. By the time the stop button is released, the Ma contact of the starter has opened, blocking the circuit to the starter coil, and the Mb contact has closed, turning on the green indicating light. The motor can only be restarted by once again pushing the start button. Voltage Self-Protection, also known as undervoltage protection, is an important protection characteristic of the three-point control circuit. The action of this characteristic can be described by again noting that when the start button for the three-point control circuit in Figure 30 is pushed, the contactor coil is energized, and the Ma auxiliary contact seals the coil circuit closed. Following this, if the line voltage dips too low or fails altogether, the coil will not be able to hold the contacts closed. Generally, the contactor coil is unable to hold the contacts closed if the voltage falls below 50% to 60% of normal. Thus a prolonged (more than a few cycles) drop of voltage at the starter terminals can cause the starter to open. Should the starter open due to voltage failure, the Ma contact also opens releasing the seal-in connection across the coil. As a result, the starter cannot reclose on return of voltage. In order to close the starter after it has opened because of low voltage or voltage failure, the start button must be pushed again. This voltage protection characteristic of the three-point control circuit eliminates the hazard of uncontrolled restarting of a motor.
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Seal-In Contact Ma is an auxiliary contact physically located on the main starter contactor and mechanically linked to operate in unison with the main contacts. It is a normally open contact, meaning that it is in the open position when the contactor coil is de-energized. The Ma contact is often referred to as the seal-in contact since, as described above, it is used to seal in the circuit that energizes the contactor coil after the start button is pushed. The main contactor has a normally closed auxiliary contact identified as Mb. The Mb contact is commonly used for operation of indicating lights or other control functions. When needed, an Mb auxiliary contact can be added to a contactor as an accessory attachment. Two-Point (Hand-Off-Auto) The two-point control circuit, as shown in Figure 31, uses a position type selector switch in place of pushbuttons. The position-type switch is similar to the pushbutton in the sense that it serves the same function, which is to energize the control circuit. However, unlike the momentary action of the pushbutton, the position-type selector switch, once set, maintains its contact engagement without the need of a seal-in interlock. Position-type switches are normally provided with either two or three selectable positions. The two-point control circuit gets its name from the fact that this arrangement requires two points of connection between the source of control voltage (terminal 1 of the control-circuit fuse) and the contactor coil. The two-point control circuit in Figure 31 shows the use of a three position switch which offers a third or auto position for use when it is desired to switch the control of the motor to an external source. With reference to Figure 31, the operation of the two-point control circuit can be described beginning with the manual movement of the selector switch to the hand position. Operating the selector switch to the hand position energizes the starter contactor coil, which in turn closes the main contacts and allows current to flow to the motor terminals. Because the selector switch maintains engagement, it does not require a seal-in circuit and thus remains in the closed state until manually changed. When it is desired to stop the motor, the selector switch is manually operated to the off position. This action de-energizes the contactor coil and opens the main contacts to stop the motor. A unique characteristic of the two-point control circuit is that following a power failure, the motor will restart upon return of power. As a result, the two-point control scheme is typically used in cases where the motor is required to be controlled by a remote device, such as a thermostat, pressure switch, float switch, or limit switch.
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Figure 31. Full Voltage Non-Reversing Motor Starter (Two-Point Control Circuit)
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Overload Relay Contact Figures 30 and 31 show the normally closed contact of the overload relay (marked OL) in series with the starter contactor coil M. When an overload condition occurs, the overload contact opens, de-energizing the contactor coil and stopping the motor. Automatic Reset of the overload contacts after operation and cooling is a feature provided on some overload relays. The automatic reset is a convenient function for use with motors located in a remote areas. Relays having the automatic reset feature can also be adjusted and used in the manual reset mode. The manufacturer normally furnishes this type of relay set to the manual reset mode. The customer then has the option of adjusting it to the automatic reset mode. Manual Reset of overload relays is the more commonly used type of reset mode. This mode provides added safety by requiring an intentional reset of the relay before the motor can be restarted. In most cases, this prompts an inspection by the operator to determine the cause of trip before restarting. To accomplish a manual reset, the operator, following an overload trip and cool down period, must go to the overload relay location and physically push or operate the reset button (plunger). For two-point control circuits, the manual reset function is preferred to eliminate the hazard of uncontrolled restarting of motors. Run/Stop Indicator (Pilot) Lights Run and stop indicating (pilot) lights are optional pilot devices for motor starters. The standard practice is to use a green light to indicate that the motor is switched-off (deenergized and not running), and a red light to indicate that the motor is switched-on (energized and running). As illustrated in Figures 30 and 31, and described above, the red light is connected directly across the terminals of the starter contactor coil and thus is turned on and off in unison with the energizing and de-energizing of the coil. Operation of the green light is controlled by the normally closed auxiliary contact Mb and thus is switched on and off directly opposite that of the red light.
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Medium Voltage Control Logic The control logic for medium voltage motor starters is very similar to the control logic used for low-voltage starters. However, there are some differences. Two of these differences include the use of interposing relays and the use of current transformers. The following paragraphs describe the reasons for using these components. Interposing Relay Interposing relays are special relays used in the control circuits of larger size contactors. The relays interface (or interpose) between the relatively high coil current required by the large size contactors and the pushbuttons or control contacts used to switch-off or break their current. As an example, Figure 32 shows one type of medium voltage starter that uses an interposing relay in its control circuit for this purpose.
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Figure 32. Medium Voltage Starter With Interposing Relay and Current Transformers
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Closing the start button of the control circuit shown in Figure 32 energizes the coil (MR) of the interposing relay and causes its three contacts (labeled MR) to close. Closing MR contacts in turn energizes the contactor coil (M) which closes the main contacts that supply current to the motor terminals. In this manner, the relatively high current required by the main contactor coil (M) is switched on and off by the two higher current rated contacts of the interposing relay, while the start and stop pushbuttons need only make and break the relatively lower current of the interposing relay coil. To give an example of the relatively higher currents required by larger size contactor coils, refer to the discussion in the previous Information Sheet Control Circuit Components, and the relevant figures, Figure 22 (Typical Operating Characteristics for AC Coils ) and Figure 23 (Typical Operating Characteristics for DC Coils ). The data provided in these figures shows the volt-ampere burden of the contactor coil increases in accordance with the size of the contactor. With reference to Figure 22, it is noted that the coil for a NEMA size 0 contactor (in the open position) presents a burden of 160 VA to the control circuit. However, larger size contactors present larger burdens, with a size 6 contactor representing a burden of 2900 VA. If a contactor coil with a burden of 2900 VA were applied to a 120-volt control circuit, the control contacts (i.e. pushbuttons) would be required to break coil currents of approximately 24 amperes. Noting the relatively high coil current required for larger size contactors, refer to Figure 6 (Ratings and Test Values for AC Control Circuit Contacts at 50 or 60 Hertz) of the previous Information Sheet and consider the amount of current that control contacts are capable of breaking. As seen in Figure 6, the breaking current ratings for typical control contacts are much lower than the expected coil current of larger size contactors. Even heavy duty control contacts (i.e. A150, A300, A600) are limited to breaking current ratings of 6.0 amperes. As a result, control circuits used to operate larger size contactors (typically size 5 and larger) normally require the use of an interposing relay. For combination starters, provided by manufacturers, the need for, and sizing of, interposing relays is done by the manufacturer without need of specification from the customer.
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CT Secondary Circuit Medium voltage motor starters normally use current transformers (as shown in Figure 32) to supply current to the thermal elements (heaters) of the overload relays. Current transformer are used for two reasons. First, the line voltage supplied to the motor terminals by medium voltage starters is nominally in excess of 1000 volts. Within Saudi Aramco, medium voltage starters are identified as being 5 kV class for use on 4160 volt circuits. Since overload thermal elements are rated for direct in-line use on circuits rated 600 volts AC and below, they can not be directly connected to higher voltage lines. As a result, insulated current transformers are used as an insulating interface between the higher voltage bus and the 600 volt rated thermal elements. The second reason for use of current transformers in medium voltage starters (and lowvoltage starter using large size contactors) is when there is a need to step down the level of current supplied to the thermal elements. As an example, manufacturers typically offer thermal elements for direct in-line use at current levels up to approximately 135 amperes. Above this current level, it is necessary to use a current transformer to step down the level of current to match the current rating of the thermal element. For comparison information, consider that NEMA size 00 contactors are rated at 10 amperes while size 5 contactors are rated at 300 amperes and size 9 contactors are rated at 2500 amperes. As a result, contactors of NEMA size 5 and larger typically require the use of current transformers to supply current to the overload relay thermal elements.
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NEC Requirements Accidental Grounds Accidental grounds occurring in a motor control circuit fed from an intentionally grounded source, can result in unwanted motor starts if the starting devices (pushbutton, limit switch, pressure switch, etc.) are not properly located. As an example, Figure 33 shows a control circuit with the pushbuttons located in the ground leg feed to the contactor coil. With this arrangement, an accidental ground at any of the points (A, B, or C) indicated in the figure will result in an unwanted start of the motor.
Figure 33. Example of Incorrect Control Circuit Wiring
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The National Electric Code recognizes that this condition can occur where damage to the control circuit, especially long wiring runs to remote pushbutton stations, is a potential problem. To protect against this problem, NEC Article 430-73 requires that where one side of the motor control circuit is grounded, the motor control circuit shall be so arranged that an accidental ground in the remote-control devices will (1) not start the motor, and (2) not bypass manually operated shutdown devices or automatic safety shutdown devices. Figure 34 shows a control circuit arrangement that satisfies the NEC requirement and prevents unwanted starts due to accidental grounds. The important step taken in wiring the circuit shown in Figure 34, is that care has been taken to place the pushbutton station in the hot leg feed to the coil, and not in the grounded leg. By taking this wiring precaution, it can be seen that the occurrence of a ground fault cannot start the motor.
Figure 34. Example of Correct Control Circuit Wiring
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Voltage Limitations A number of different voltage levels, both AC and DC, are used for motor starter control circuits. Among these are included AC voltage levels of 24, 48, 110, 120, 200, 208, 220, 240, 380, 440, and 600 volts. DC voltage levels include 24, 48, 125 and 250 volts. Evidence of the large number of voltage levels in use can be seen by reviewing a manufacturers catalog and noting the number of different voltage ratings available for contactor coils. The National Electric Code addresses circuit arrangement (such as proper grounding described above), protection requirements, and wiring requirements for control circuits, but it does not address the level of voltage to be used. Although a large number of voltage levels are in fact used, only a few are used extensively. For most common applications, the level of control voltage is 120 or 240 volts AC with some uses extending to 480 volts. As described previously, a number of motor starter control circuits use a control power transformer (CPT) to step down the level of voltage used in the control circuit for isolating and safety purposes. In all cases, when a control power transformer is used, the voltage is reduced to between 110 and 120 volts AC. As a result, the control voltage level for circuits with control power transformers is 110 to 120 volts AC. In accordance with 16-SAMSS-503, Saudi Aramco requires that all low-voltage starters be provided with control power transformers unless otherwise specified. Medium voltage starters normally use a control power transformer as part of their standard design.
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FULL VOLTAGE REVERSING CONTROL CIRCUIT LOGIC The full voltage reversing motor starter is used where it is necessary to be able to start and run a motor in either direction. The direction of rotation of three-phase induction motors is easily reversed by simply interchanging any two of the three line connections to the motor. Reversal of the motor connections is accomplished through control of the contactors mounted in the motor starter. This Information Sheet describes several types of control logic used in fullvoltage reversing starters. Control Logic Description Full-Speed Reversing (Small Motors) One type of control logic used in full-voltage reversing starters is the full-speed reversing logic. The circuit arrangement for this type logic allows the direction of a motor to be reversed without pushing the stop button. This mode of operation has the advantage of reversing the direction of the motor in the shortest possible time. However, use of this type of logic is acceptable only for small motors with relatively low mass and thus low inertia. The circuit arrangement for full-speed reversing is shown in Figure 35. The arrangement of this circuit is basically the same as for all full-voltage reversing starters, except that the forward pushbutton and the reverse pushbutton have an additional normally closed contact block. The starter has two contactors, one connected to apply the three phases to the motor so that the motor starts and runs in the forward direction. The other contactor is connected so that when it closes, two of the lines to the motor are interchanged, thus reversing the direction of rotation of the motor.
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Figure 35. Full Voltage, Full-Speed Reversing Motor Starter
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For the circuit shown in Figure 35, starting the motor and operating it in the forward direction is initiated by closing the forward pushbutton. This action energizes the forward contactor (F), which in turn closes the main contacts to the motor terminals, thus starting the motor in the forward direction. The same action that closes the normally open contact of the pushbutton also opens its normally closed contact. This temporary open circuit prevents an unwanted start in the reverse direction. As the forward contactor operates, it causes its auxiliary contacts to operate also. The normally open auxiliary forward contact (Fa) closes to seal in the forward coil circuit, and the normally closed auxiliary forward contact (Fb) opens to block the reverse contactor coil circuit. To reverse the direction of the motor (without first pushing the stop pushbutton), simply push the reverse pushbutton. The opening of the normally closed contact of the reverse pushbutton causes the coil circuit for the forward contactor (F) to momentarily open. The circuit for the reverse contactor coil (R) circuit momentarily closes. When the forward contactor opens, it operates its auxiliary contacts (Fa , Fb). Fa opens to keep the forward (F) coil circuit open, while Fb closes to allow the reverse coil (R) circuit to energize. When the reverse contactor picks up, it closes it main contacts to the motor terminals, which in this case causes lines L1 and L3 to be interchanged, reversing the direction of the motor. Auxiliary contacts Ra and Rb operate in unison with the reverse contactor. The normally open Ra contact closes to seal in the reverse coil circuit, while the normally closed Rb contact opens to block the energizing of the forward coil circuit.
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Stop Before Reversing (Medium Motors) The stop before reversing logic is generally used for medium size motors. Stopping the motor first, before reversing its direction, eliminates the overcurrent surge and potentially damaging mechanical stress that can result with the attempt to rapidly reverse a large rotating inertia (load). Figure 36 shows the circuit arrangement for a stop before reversing logic. The basic difference between this circuit and the one given in Figure 35 is the arrangement of the pushbutton contacts.
Figure 36. Full Voltage (Stop Before) Reversing Motor Starter
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Operation of the circuit in Figure 36 begins by closing the forward pushbutton to energize the forward contactor coil (F). This action closes the main forward contacts to the motor terminals starting the motor in the forward direction. In sequence with this action, auxiliary contact Fa closes to seal in the forward coil (F) circuit, and auxiliary contact Fb opens to block the reverse coil (R) circuit. To reverse the motor when it is running in the forward direction, it is necessary to first push the stop pushbutton. Pushing the stop pushbutton deenergizes the forward contactor, which in turn opens the main forward contacts and allows Fa to open and Fb to close. At this point, the reverse pushbutton can be pushed to energize the reverse contactor coil circuit. In sequence then, the main contacts of the reverse contactor close (reversing motor lines L1 and L3), Ra closes to seal in the reverse coil circuit, and Rb opens to block the forward coil circuit. The circuit logic for the stop before reversing starter requires only that the stop button be pushed before an attempt is made to reverse the direction of the motor. Whether the motor is allowed to come to a complete stop before actually reversing is an option of the operator based on the motors size and inertia. Time-Out Before Reversing (Large Motors) Large motors must be brought to a complete stop before attempting to reverse their direction. This precaution is necessary because of the large mass and resulting high inertia of the motor. This inertia could cause intolerably high motor current and possible mechanical damage if direction reversal where attempted while the motor was still turning. To accomplish this mode of operation, a circuit logic referred to as time-out before reversing is used. The circuit arrangement for this logic is identical to the one shown in Figure 36 with one exception. The exception is that either a timing relay or speed sensor is added to the circuit. When a timing relay is used, the relay is connected to begin its timing cycle whenever the stop pushbutton is pushed. The timing relay contacts prevent energizing the contactor coil for the opposite direction until after the relay has completed its predetermined time cycle. The cycle is preset to allow the motor sufficient time to come to rest. When speed sensors are used, the control contacts for the sensors are connected in series with the contactor coil circuits. The sensors continuously monitor the speed of the motor. On pushing the stop pushbutton, the sensor control contacts prevent energizing the contactor coil for the opposite direction until after the motor comes to a stop.
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Mechanical and Electrical Interlocks All reversing starters have two magnetic contactors mounted in one enclosure. The contactors provide for connection of the power leads to the motor terminals. One contactor (forward contactor) is connected to the apply the three phases to the motor so that the motor starts and runs in the forward direction. The other contactor (reverse contactor) is connected so that when it closes two of the lines to the motor are interchanged, thus reversing the direction of rotation of the motor. With regard to the operation of the two contactors, it necessary that they be interlocked to prevent both of them from closing at the same time. If both contactors were to close at the same time, the result would be a dead short circuit across two of the phases. Interlocking is used to prevent this condition from happening. Both mechanical and electrical interlocks are used. Mechanical interlocks typically use an insulated linkage fastened between the moving assemblies of the two contactors to prevent their simultaneous closing. Electrical interlocking circuits vary in purpose and complexity, but the basic technique consists of using normally open and normally closed contacts in both the forward and reverse coil circuits to maintain each coil circuit open while the other is closed.
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REDUCED-VOLTAGE AUTOTRANSFORMER CONTROL CIRCUIT LOGIC Reduced-voltage starters are used where full-voltage starting can cause serious problems. For some applications, the use of a full-voltage starter with its typical 600% starting current causes unacceptable voltage disturbances on the electrical power system. In other cases, the relatively high starting torque that accompanies full-voltage starting may mechanically overstress the driven equipment. For these, as well as other reasons, reduced voltage starters are sometimes used instead of full-voltage starters. The reduced-voltage autotransformer is one type of reduced-voltage motor starter used for this purpose. The following paragraphs describe the control logic and operation for this type of starter. Control Logic Description The autotransformer motor starter incorporates the use of autotransformer coils to supply a reduced voltage to the motor during starting. Figure 37 shows a typical control circuit for an open-delta type autotransformer starter while Figure 38 presents an equivalent single-phase circuit for the starter at the instant of starting.
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Figure 37. Reduced-Voltage Autotransformer Motor Starter
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Figure 38. Equivalent Single-Phase Circuit for Autotransformer Motor Starter The basic principle used to apply reduced voltage to the motor can be described by referring to the equivalent circuit show in Figure 38. To begin with, assume that the motor is connected to the 50% tap on the transformer. With the motor connected to this tap, 50% of the full voltage is applied to the motor, therefore the current Im drawn by the motor is 50% of the full-voltage starting current. However, by transformer action, the line current IL (the primary current of the transformer) is only 50% of the motor current (the secondary current of the transformer). Thus, the line current drawn from the system is only (0.50)2 or 0.25 (25%) of the full-voltage starting current. The reduction of starting torque is proportional to the same percentage-tap-squared factor as for the reduction in starting line current. With reference to Figure 37, the operation of the control circuit that allows the autotransformer to apply reduced voltage and start the motor begins with the closing of the start pushbutton. This action energizes and closes start contactor S, which connects each autotransformer to the line and energizes the motor through the transformer taps. At the same instant, the timing relay TR is energized to begin its preselected timing cycle. As the motor accelerates toward full speed, the timing relay operates to open contactor S, which disconnects the autotransformer and closes run contactor R, which connects the motor directly to the lines so that it runs normally on full voltage.
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Mechanical and Electrical Interlocks Interlock protection for the S and R contactors is necessary to prevent their being closed at the same time. A review of the control circuit in Figure 37 shows that if both contactors were permitted to close at the same time, a portion of the autotransformer winding would be shorted out placing an overvoltage on the remaining portion. To prevent this condition from happening, the S and R contactors are electrically interlocked by the normally open and normally closed contacts of the timing relay (TR). As a result of their placement in the control circuit, the timing relay contacts maintain each coil circuit open while the other is closed. In addition to electrical interlocking, it is common practice for the S and R contactors to be mechanically interlocked. Mechanical interlocking of the S and R contactors is done by connecting their moving assemblies with an insulated mechanical link. Transition Timer For the autotransformer starter shown in Figure 37, the switching operations are made by the magnetic contactors in combination with the timing relay TR. The timing relay, also known as the transition timer, initiates the transfer from reduced voltage to full voltage operation. The time period, beginning with the closing of the start pushbutton and continuing until the autotransformer is switched out of the circuit and full voltage applied, is called the transition time. The allowed transition time is the time estimated necessary for the motor to accelerate to full speed while at reduced voltage. The timing relay (transition timer) is preset to the allowed transition time before attempting to start the motor.
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Incomplete Sequence Timer For the reduced-voltage autotransformer starter, the autotransformer is expected to carry current only during the short starting cycle. As a result, the physical size of transformers used in these starters are smaller than the ones that would be expected to carry full current continuously. To protect against a malfunction of the control circuit that would require the autotransformer to carry current for too long a time during the start cycle, an incomplete sequence timer (TS) is connected in the control circuit. The incomplete sequence timer has a thermal element connected in a manner that causes it to begin carrying current as soon as the start pushbutton is closed. The thermal element senses the period of time that current is flowing, which in turn is the same amount of time that the autotransformer is carrying starting current. Should the current carrying time period exceed the allowed period, the TS relay contacts open. When the TS contacts opens, they open the TR coil circuit and thus disconnects the motor. Additionally, the TS timer has a thermal memory that will prevent an attempt to re-start the motor until sufficient time has elapsed to allow the heater element of the TS, and the autotransformer windings, to cool. Tap Selection Autotransformers are normally constructed with taps rated 50%, 65%, and 80%. For a specific application, the tap is selected on the criteria of starting the motor using the minimum magnitude of line current while realizing motor starting torque sufficient to overcome the counter-torque of the driven load. The motor must additionally produce a net torque sufficient to accelerate rotational masses to full speed within a period of time that is less than the duty rating of the transformer. The timer relay, TR, must be set slightly longer than the anticipated acceleration time to prevent a transition to full-voltage before the magnitude of the starting current has reduced to less than 150% of motor full-load amperes, but not longer than the duty rating of the autotransformer.
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REDUCED-VOLTAGE WYE-DELTA CONTROL CIRCUIT LOGIC Another type of reduced-voltage motor starter is the wye-delta starter (Figure 39). This type of starter uses the method of connecting the motor windings into a wye configuration to start and then switches the windings into a delta configuration to run. The following paragraphs describe the logic for this type of starter.
Figure 39. Reduced-Voltage Wye- Delta Motor Starter
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Control Logic Description A six-lead motor that is normally connected delta for rated voltage can be started with reduced inrush current and torque by connecting the windings wye during acceleration. After the motor is accelerated to full speed, magnetic contactors quickly reconnect the windings to delta for rated operation. Starting the motor in this manner, with the windings connected in a wye connection, is equivalent to starting on a 57% autotransformer tap and providing the motor with 33% of full-voltage starting torque. Operation of the control circuit shown in Figure 39 begins by closing the start pushbutton. This energizes and closes start contactor S which closes Sa and picks up contactor 1M. At the same time Sb opens to block 2M from picking up. The main contacts of the S contactor connect motor terminals T4, T5, and T6 to make a wye connection. The 1M contacts connect the supply lines L1, L2, and L3 to the motor terminals T1, T2, and T3. With the windings connected in this wye arrangement, the motor accelerates to full speed. With the closing of Sa, the time delay relay TR is energized and begins timing the transition (starting) period. After the timing relay TR times out, its contacts open, dropping out contactor S. Although auxiliary contact Sa opens, contactor 1M remains closed due to the sealed-in 1Ma auxiliary contacts. Auxiliary contact Sb closes to pickup 2M. With 1M remaining closed, the 2M contacts now connect the motor windings into a delta circuit by connecting supply lines L1, L2, and L3 to the motor terminals T4, T5, and T6. The motor now operates at full (delta connected) voltage. The wye-delta type starter has the advantage of being relatively inexpensive since it does not require the use of resistors or autotransformers. However, offsetting this advantage are a few disadvantages. First, there is no method of adjusting the starting torque. If the one-third normal torque cannot turn the motor or should the acceleration be too slow, the wye-delta starter is not a practical choice. Second, use of this type starter requires a special motor with all six leads brought out to the terminal box. Finally, the starter as shown is an open transition type, which means the motor is briefly disconnected for the transition from wye to delta.
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Mechanical and Electrical Interlocks Interlock protection for the S and 2M contactors is absolutely necessary since the closing of both contactors at the same time would result in a three-phase short circuit directly across the power supply lines. To prevent S and 2M from closing at the same time, they are interlocked both electrically and mechanically. Electrical interlocking is accomplished using the normally closed Sb and 2Mb auxiliary contacts to maintain each coil circuit open while the other is closed. Mechanical interlocking of the S and 2M contactors is accomplished using the standard manner of interconnecting their moving assemblies with an insulated mechanical link. Transition Timer The reduced-voltage wye-delta starter, starts the motor with the windings connected in a wye configuration and then, using its contactors, goes through a transition to a delta winding configuration. The time required for the motor to accelerate to full speed while connected in wye is referred to as the transition time and is preset by the setting of the timing relay TR. When the TR relay times out, its contacts open, dropping out the starting contactor (S), which in turn switches in the 2M contactor that completes the transition by reconnecting the winding in delta. Allowing the motor to run for a longer than necessary time period while connected in the wye configuration does no harm. However, in the wye configuration, the motor has only one-third of its full-load torque capability, and it is necessary to transition to the delta connection to provide the motor with full torque capability.
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MULTI-SPEED CONTROL CIRCUIT LOGIC Full voltage magnetic starters are available for operating multi-speed motors at different speeds. A typical multi-speed starter consists of a group of contactor assemblies in a single enclosure, each contactor operating the motor at one speed. The operating logic of multi-speed starters is determined by the principle on which multispeed motors are based. In brief, this principle states that given a fixed frequency of AC supply voltage, the speed of rotation of a three-phase motor depends on the number of poles in the motor. An increase in the number of poles will decrease the motor speed. Thus, changing the number of poles in a motor, changes the speed at which it rotates. Multi-speed starters are basically used with two types of AC squirrel-cage induction motors that provide for changing the number of their poles to accomplish multi-speed operation. One type is a motor that has one winding, but the winding is designed in a manner that allows it to be reconnected to change the number of its poles. The winding for this motor is known as a consequent pole type and can be reconnected to obtain two different numbers of poles, with speeds in a ratio of 2-to-1. This motor is commonly referred to as a two-speed, singlewinding motor. The other type is a motor that has separate windings that provides for changing connections to give a different number of poles. In this case, each winding produces a certain number of poles for a certain speed, but the two speeds do not have to be in the ratio of 2-to-1. And, if one or both of the separate windings on the stator are of the consequent-pole type, then the motor may operate at 3 or 4 speeds. This type is typically called a two-speed, two-winding motor. The following paragraphs describe the control logic for a two-speed two-winding starter and a two-speed single-winding starter. Control Logic Description Two-Speed Two-Winding Motors Figure 40 shows the control logic for a typical multi-speed starter for a two-speed twowinding motor. As described above, this type of logic accomplishes the changing of motor speed by separately and individually energizing the two windings of the motor. To operate the motor at low speed, the low speed start pushbutton (L) is closed. This action causes the low speed contactor coil (L) to pickup, closing the main contacts to energize the low speed winding. Auxiliary contact La then closes to hold the coil circuit closed and allow the motor to continue running at low speed.
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To change to high speed operation, the high-speed pushbutton is closed. The mechanical linkage between the normally open and normally closed contacts of the high-speed pushbutton cause the circuit to the low-speed coil to be opened (de-energizing the low-speed winding), before the circuit to the high-speed coil is allowed to close. The high-speed contacts close, energizing the high-speed winding. Auxiliary contact Ha closes to seal-in the high-speed coil circuit and allow the motor to continue operating at high speed. Pushing the stop pushbutton at any time opens both contactor coil circuits and stops the motor.
Figure 40. Multi-Speed Starter for Two-Speed Two-Winding Motor
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Two-Speed Single-Winding Motors Figure 41 shows a typical multi-speed starter used for a two-speed single-winding motor. In this example, the two different speeds are accomplished by using the starter contactors to reconnect the single winding from a delta connection (for low speed) to a wye connection (for high speed). However, it is important to note that the multi-speed starter shown in Figure 41 differs from the wye-delta starter described above in Figure 39. The basic difference is that the wye-delta starter described in Figure 39 does not change the effective number of poles in the motor it controls. It only reconnects the winding from wye to delta and thus operates the motor at the same speed for each connection. On the other hand, the starter shown in Figure 41 actually changes the number of poles by reconnecting the individual circuits of the winding. For the low-speed delta connection, the starter contactors connect the motor winding in a configuration that places two circuits per phase in series (i.e. winding circuit T4T1 is in series with T1-T6, T6-T2 is in series with T2-T5, and T5-T3 is in series with T3-T4). For the high-speed wye connection the motor winding is reconnected for two winding circuits in parallel per phase (i.e. winding circuit T4-T1 is in parallel with T4-T3, T6-T1 is in parallel with T6-T2, and T5-T2 is in parallel with T5-T3). Low-speed operation of the starter shown in Figure 41 begins with the closing of the lowspeed start-pushbutton (L). This action picks up the low-speed contactor and connects the main supply lines to motor terminals T1, T2, and T3 (the low-speed, two-series, delta configuration). At the same time, auxiliary contact La closes to hold the coil circuit closed and allow the motor to continue running at low speed. To change to high-speed operation, the high-speed pushbutton is pushed. The mechanical interlock between the low- and high-speed pushbuttons causes the circuit to the low-speed coil to be opened (de-energizing the delta winding configuration), while the circuit to the high-speed coil is closed. The high-speed contactor has five mechanically interlocked main contacts that close at the same time reconnecting the winding to a two-parallel wye configuration. Specifically, motor terminals T1, T2, and T3 are connected together by two of the contacts to form the star point of the wye, while the three supply lines are individually connected to motor terminals T6, T5, and T4 to complete the three parallel legs of the wye. At the same time, auxiliary contact Ha closes to seal-in the high-speed coil circuit and allows the motor to continue to operate at high speed. Pushing the stop pushbutton at any time opens both contactor coil circuits and stops the motor.
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Figure 41. Multi-Speed Starter for Two-Speed Single-Winding Motor
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Mechanical and Electrical Interlocks For the two types of multi-speed starters described above, interlock protection is necessary to prevent short circuits. Both types of starters require that the low-speed and high-speed contactors be interlocked to prevent them from being closed at the time. For the examples shown, the interlock between the contactors is accomplished with the standard insulated mechanical link connected between their moving assemblies. In addition to mechanical interlocking, auxiliary contacts Hb and Lb electrically interlock the H and L contactors. Multiple O/L Relays Multi-speed starters require the use of overload relays to sense overload conditions and stop the motor in the same manner as other type starters. This includes connecting the overload relay thermal sensor (heater) in the motor current circuit to sense a potential overload, while the relay contacts are connected in the control circuit to open the contactor coil circuit when necessary. However there is one difference. The difference is that for two-speed starters controlling two winding motors (Figure 40), it is necessary to use two overload relays, instead of just one, to protect the two windings. This is necessary for two reasons. First, the starter, when controlling the two-winding motor, energizes only one winding at a time. As a result, it is necessary to individually connect an overload relay in each winding circuit to provide overload protection for each winding. The second reason for requiring two separate overload relays for the two-winding motor is that each winding has a different current rating. As a result, the current rating for each set of thermal elements must be different in order to provide the correct level of overload protection for each of the two windings. Figure 41 shows a two-speed single-winding motor protected with two overload relays using six thermal elements (heaters) connected in the six motor lines (T1 through T6). However, this motor could be protected using only one overload relay with three thermal elements. To protect the motor using only one overload relay, the thermal elements must be electrically connected in motor line leads T1 T2, and T3. Connecting the six thermal elements T1, T2, and T3 places them in the path of the motor current for both the low-speed and high-speed winding connection. In comparison, if the thermal elements where connected in the circuit at motor terminals T6, T5 and T4, the thermal elements would only be effective when the highspeed contactor was closed.
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TYPICAL ELECTRONIC (SOLID-STATE) CONTROL CIRCUIT LOGIC Electronic solid-state motor starters provide reduced voltage starting for AC squirrel-cage induction type motors. The functional operation of the solid-state starter is similar to that of reduced voltage magnetic type starters, however, the technology and components used are different. A typical solid-state motor starter (as shown in Figure 42) uses power type SCRs (silicon controlled rectifiers) to control the flow of current to the motor and electronic sensing devices to detect overload and fault conditions. Solid-state starters are available only as lowvoltage starters for nominal voltage ratings of 208V through 575V. Figure 43 gives an example of the ratings offered by one manufacturer for one style of solid-state starter. With regard to this figure, it should be noted that the nominal horsepower ratings are listed for reference only, and the starter should be selected based on motor full-load amperes. Saudi Aramco standards do not, in general, specify the use of solid-state type starters for low voltage motors. However, for completeness, and as background information for the Participant, a description of typical control logic for solid-state starters is included.
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Figure 42. Typical Electronic Solid-State Motor Starter
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Figure 43. Typical Manufacturer Ratings for Solid-State Starters
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Control Logic Description The typical solid-state starter uses six high-current SCRs, arranged two per pole (for both positive and negative current flow), to switch the motor load current on and off. Turning the SCRs on and off is accomplished by sequentially timed voltage pulses supplied from an electronic firing circuit to the gate terminals of the SCRs. The conduction period of current, and consequentially the starters output voltage level, is made to increase whenever the control-logic module delivers gate pulses earlier in the forward-bias period of each SCR. Voltage level decreases when the pulses are delayed. Voltage output is zero whenever gate pulses are interrupted. The distinction of the SCRs to control the voltage and current level supplied to the motor, coupled together with the logic of the internal electronic circuits, give the solid-state starter the capability of providing soft starts. The soft starts are governed by using one or both of two adjustable functions controlled by the starter logic circuit. One is a voltage/time ramp and the other is a current-limit function. The voltage/time ramp is the more basic of the two functions. For this function, the voltage supplied by the SCRs to the motor terminals is controlled in a manner that causes the voltage to increase linearly with time until full line voltage is applied (Figure 44). The start of the ramp is modified by adding an initial voltage step as shown in Figure 44. For typical solidstate starters, this voltage step is adjustable from 10 to 80% of full motor volts. The reason for including this initial voltage is to adjust for the negligible level of motor torque at low voltage. If the voltage ramp were allowed to start at zero, the motor may not begin to move until several seconds after initiating the start.
Figure 44. Voltage Ramp Function for Solid-State Motor Starter
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The second adjustable function used to control the soft start operation is the current-limit function (Figure 45). For this function, load current is sensed via the current transformers, and compared with a preset limit (typically 300 to 550%) of full-load current. The current allowed to flow through the SCRs to the motor is adjusted to remain at or below the preset value during the starting period. A precaution for this adjustable function is that when adjusted for very low currents, and starting a partially loaded motor, there is a possibility that the motor may not rotate, drawing the limited level of starting current, until it overheats or trips out.
Figure 45. Torque Speed Characteristics for Current-Limit Function
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Solid-State Interface Devices Solid-state starters are supplied together with their electronic overload protection, current sensors and logic controls packaged in a NEMA type enclosure as an integral package. Start, stop and reset pushbuttons are normally mounted on the enclosure cover together with an array of indicating lights and LEDs (light emitting diodes) that report the status of such parameters as motor operation, ramp starting functions, phase rotation, undervoltage trip, overcurrent trip, phase loss trip, and phase current unbalance. Interface connections to the starter basically include connection of the three power supply line leads and three motor leads. Pushbuttons for local operation are mounted on the enclosure cover, however, the starter is equipped with a terminal strip that allows connection of remote pushbuttons for start, stop, and reset functions at a 120 volt control level. An external trip signal is supplied from the starter logic control circuit for connection to the customers protective device. Normally open and normally closed auxiliary contacts contained in the starter assembly are also brought out to the terminal strip for use by the customer. Current Feedback The control for this type of starter is accomplished by the internal electronic logic circuits monitoring and comparing the current and voltage signals from the sensors. In this manner, the voltage and current feedback signals are used to control the soft start voltage ramp and current-limit functions on starting, the switching-off of the SCRs for unacceptable overloads, and as necessary the sending of a trip signal to the external protective device to provide protection for short circuit, undervoltage, and single-phase conditions. Voltage feedback is accomplished with a direct wiring connection between the starter line leads and the control logic circuit as shown in Figure 42. This method of feedback is possible because the solid-state starters are available only as low-voltage starters (208V to 575V), thus the voltage signal can be fed directly to the logic circuit and reduced as necessary with resistance dividers. Current feedback must be achieved with the use of current transformers. The level of current in the motor leads is too large to use directly in the logic circuit and must be reduced by current transformers. The current transformers are sized in accordance with the rating of the starter and the requirements of the control logic circuit. The current transformers are then supplied as an integral part of the starter.
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Programmable Features Solid-state starters have a number of functions that can be programmed by the customer to satisfy specific application requirements. Some of the functions typically available for programming include: Full-Load Running Current Trip - The current trip function provides overload protection for the motor and is typically programmable over a range of 100 to 120% of full-load current. The current trip circuit works on an inverse time principle, similar to a thermal overload relay or circuit breaker. Current trip settings are normally made in accordance with motor service factors. Start Time Delay - The start time delay function is used to inhibit the inverse time current trip while the motor is being accelerated to speed. Typical maximum start delay times up to 20 seconds are available for programming. Current Limit - Programming of this function controls the available starting current (which is proportional to torque) during the starting period. The torque in turn determines the time required for a motor to accelerate to full speed. Typical ranges available for programming are 200 to 500% of full-load current. Time Ramp - This function allows programming of the rate at which voltage is applied to the motor terminals during startup. By starting the motor with a controlled voltage ramp, inrush current is limited and acceleration is smooth. A time range of from 1 to 40 seconds is typically available for programming the voltage to increase linearly up to the full-rated voltage of the motor. Initial Voltage - This function works together with the voltage/time ramp function to allow the ramp to start with an initial voltage step instead of starting from zero. Programming the voltage/time ramp function to start from zero could result in the motor standing idle during the first few seconds of the starting period. The range available for programming the initial voltage step is typically from 10 to 80% of full motor voltage.
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CIRCUIT BREAKER CONTROL CIRCUIT LOGIC Low-voltage and medium-voltage power circuit breakers are generally used for control of larger size motors. The types of breakers commonly used for this purpose include magnetic air, vacuum, and SF6 gas power circuit breakers. The breakers are typically operated by a spring charged mechanism with a control circuit similar to the one shown in Figure 46. The operating logic of the breakers control circuit is the control logic for this type controller. In accordance with SAES-P-114, Saudi Aramco specifies that low-voltage power circuit breakers be used as the controller for induction motors 600 volts or less and greater than 100 horsepower. For induction and synchronous motors 4000 volts or greater and less than 1500 horsepower, a power circuit breaker may be used as the controller. For induction and synchronous motors greater than 1500 horsepower, a power circuit breaker must be used as the controller.
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Figure 46. Standard Breaker Control Scheme (With DC Close, DC Trip and AC Spring Charging Motor)
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Control Logic Description The breaker control circuit shown in Figure 46 is typical of the type used for many power circuit breakers. An AC supply source drives a universal motor to charge the closing springs of the operating mechanism. DC control voltage is used to actuate the closing or tripping mechanisms of the breaker by briefly energizing the coils of the spring release (closing) solenoid or the trip solenoid. Auxiliary and limit switches are used to assure correct sequencing of the control operations. The following paragraphs describe the control logic for the main components of this circuit. Circuit Breaker Control Switch Closing and opening of the circuit breaker is initiated by operation of the circuit breaker control switch (similar to the type described above in Figures 10 through 14). This switch is normally mounted on the front panel of the switchgear enclosure or on a remote control panel. The contacts of this switch are identified in the circuit diagram of Figure 46 as CS/T (control switch trip) and CS/C (control switch close). Operating the close contacts (CS/C) energizes the spring release coil (SR), which in turn releases the energy in the mechanism closing springs and closes the main contacts of the breaker. Operating the trip contacts (CS/T) energizes the trip coil (TC), which releases the energy in the mechanism opening springs and opens the main contacts of the breaker. However, successful closing and/or tripping of the breaker depends on the status of other auxiliary, limit, and relay contacts. Details of the closing logic are described below under the heading of Closing Solenoid, while details of the tripping logic are described under the heading of Trip Solenoid.
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Closing Solenoid In normal operation, the mechanism closing spring (the source of energy used to physically close the breaker) is charged by the spring charging motor as soon as control power is applied to the breaker ( AC power to secondary contact-block points 55 and 56). The motor limit switch (LS1), which is normally closed when the spring is discharged, opens after the spring is charged and disconnects the motor. At the same time, motor limit switch (LS2), which is normally open when the spring is discharged, closes after the spring is charged to prepare the spring release circuit for operation. The signal to close the breaker is initiated by closing the contacts CS/C which places the DC control voltage directly across the secondary contact-block points 6 and 7. However, energizing the spring release coil (SR) is also controlled by the status of the relay (Y), the auxiliary contacts (b), the latch check switch (LC), and the motor limit switch (LS2). For normal conditions, when the closing springs are fully charged (completely extended), the motor limit switch (LS2), will be closed. If the breaker is correctly positioned in its draw-out cell, its levering device is not engaged and the closing spring is charged, the trip latch will be fully engaged on the trip shaft and thus the trip latch switch (LC) will be closed. Also, the auxiliary switch (b) is normally closed when the breaker is open and the relay contact (Y) is normally closed when the Y relay is de-energized. Thus, with the four sets of permissive contacts closed, the SR coil is energized through Y, b, LC and LS2 when the control switch contacts CS/C are closed. Energizing SR mechanically releases the closing springs, closing the breaker, opening the limit switch (LS2), and opening the auxiliary contact (b) to disconnect the SR coil circuit. At the same time, LS1 closes to energize motor (M) and recharge the closing springs. With the opening of auxiliary contact (b), relay coil (Y) is energized through resistor (R). This action opens the normally closed contact (Y) to maintain the SR coil circuit open and prevent the re-energizing of the SR coil in the event that: a close-open operation occurs, and the closing spring has time to recharge (approximately 5 seconds), and the close signal still persists.
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Anti-Pumping Relay The principle function of the Y anti-pumping relay is to prevent close-open cycling of the breaker through any period that the close signal might remain active. Close-open cycling can occur if a breaker is closed into a fault, immediately trips in response to the fault, and then attempts to reclose because the close signal is still present. (A similar pumping can occur if the breaker is closed under normal conditions and a short or ground in the control circuit causes an unintended trip signal to be present). As described above, once the SR coil is energized and allowed to operate, the Y relay picks up through resistor R. Once energized, the Y relay remains energized until the close signal is released to allow the Y relay coil circuit to open. As long as the Y relay is picked up, its open contact prevents unwanted re-energizing of the SR coil. Trip Solenoid With the breaker in the closed position, the signal to trip the breaker is received through secondary contact-block points 9 and 10. The initiating contacts can be either the breaker control switch trip contacts (CS/T) or the protective relay contacts (PR). Closure of either set of contacts places the DC control voltage directly across the trip coil. Energizing the trip coil causes the mechanism opening spring to release, thus opening (tripping) the breaker. Two auxiliary contacts (a), which are closed when the breaker is closed, open when the breaker opens and interrupt the trip coil circuit. Relay Interface The control logic of the circuit breaker provides for tripping of the breaker by one or more protective relays. This capability is known as the relay interface for the logic circuit. The representation of a single contact, PR, on Figure 46 represents the control function of several protective relays any one of which can act alone to trip the circuit breaker. The wiring connection for the relay contacts is made directly across the control switch trip contact (CS/T).
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Indicator Lights The control circuit of Figure 46 contains two indicating lights, one green and one red. The green light is connected in the normal manner using an auxiliary contact to make and break its circuit. When energized, the green light indicates that the breaker is open. The red light serves two functions. When energized, it indicates that the breaker is in the closed state. But more importantly, when illuminated, it serves as a positive indication that the trip circuit is in fact continuous and ready to be tripped. It is capable of providing this positive indication because of the manner in which it is connected in the circuit. The red indicating light is connected directly in series with the trip coil (TC) and its auxiliary contacts (a). Spring-Operated Mechanism The type of mechanism commonly provided on low- and medium-voltage power circuit breakers is the spring-operated mechanism. This type of mechanism has two major parts: one part is dedicated to charging or storing energy in the operating springs, the other part is the assembly that opens and closes the breaker. The mechanism is typically an electrically-operated version equipped with a universal-type motor for automatic charging of the closing springs. It is equipped with a spring release device for electrically closing through a control switch, pushbutton, or other circuit making contacts. A shunt trip device is supplied for remote tripping through a control switch, relay or other device. In the absence of control voltage, or whenever desired, the closing spring can be charged by using an emergency charging handle. Once the springs are charged, hand closing and tripping of the breaker can then be accomplished by pushing close and trip plates located on the mechanisms front panel. The breaker control is so arranged that for normal operation the spring charging motor is energized as soon as control power is applied to the breaker. The motor will typically charge the closing spring in approximately 5 seconds. When the closing spring is fully charged, the motor is cut off. Releasing the closing springs to close the breaker causes the opening spring to be charged, in preparation for a trip operation. At the same time, the control circuit automatically energizes the motor to recharge the closing springs.
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GLOSSARY
air magnetic breaker
A type of medium voltage circuit breaker with its contacts in air. An electromagnet built into the arc chutes aids in extinguishing the arc. A rotary power switch designed for heavy duty control systems. A complete motor starter consisting of a disconnect device, a magnetic contactor, and protective devices for short circuit and overload. All devices are assembled in a single enclosure. A magnetic device that has sufficient capability to connect and disconnect the electric circuit of a motor under normal and overload conditions. The circuit that carries the electric signals directing the performance of the controller but does not carry the main power circuit. A component that is used in a motor starters control circuit to interface between a pilot device and the circuit that the pilot device controls. A transformer used to draw control power from the main power circuit of a motor starter. A type of motor starter that applies full voltage to the motor terminals during the starting period. Special relays used in the control circuits of larger size contactors to interface (or interpose) between the relatively high coil current required by the large size contactors and the pushbuttons or control contacts used to switch-off or break their current. A simple type of motor starter that provides full-voltage, onoff type operation for small single-phase and three-phase motors.
circuit breaker control switch combination starter
contactor
control circuit
control relay
control power transformer (CPT) full-voltage starter interposing relay
manual starter
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motor circuit protector
A magnetic-only molded case circuit breaker used in lowvoltage combination starters. This device has only instantaneous functions to protect the motor, starter, and branch circuit from short circuit and ground fault currents. A device that is used to sense an overload on a motor circuit. The most common type uses a heater that heats a bi-metallic strip that operates a set of contacts. Control and indicating devices used in motor control circuits. These include indicating lights, switches, and pushbuttons. A type of motor starter that applies less than full-voltage to the motor terminals during the starting period. A type of motor starter that provides for reversing the direction of rotation of the motor. An electric device that is designed to interpret input conditions in a prescribed manner and after specified conditions are met to respond to cause contact operation or similar abrupt change in associated electric control circuits. A contactor whose function is performed by semiconducting devices The most common type of control used to start and stop a motor. This type of control automatically starts and stops a motor depending on the set points of a pilot device. A specific type of circuit breaker designed to interrupt the arc inside a container that is under vacuum. The vacuum limits ionization of gases and makes the circuit breaker lighter and more compact.
overload relay
pilot device reduced-voltage starter reversing starter relay
solid-state contactor three-wire control two-wire control vacuum circuit breaker
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Electric Motor 5

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Engineering Encyclopedia

Saudi Aramco DeskTop Standards

Motor Starter Control Circuits

Chapter : Electrical File Reference: EEX21604

For additional information on this subject, contact W.A. Roussel on 874-1320

Electrical Motor Starter Control Circuits

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Electrical Motor Starter Control Circuits

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Figure 2. Normally Open Pushbutton

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Figure 3. Normally Closed Pushbutton

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Figure 4. Types of Contact Assembly Blocks

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Figure 5. NEMA Type Designation (Reference NEMA Std. No. 250-1991)

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Figure 10. Typical Circuit Breaker Control Switch

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Figure 12. Example of Contact Operation for a One-Stage, Six-Contact Switch

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Figure 15. Lamp-Base Styles

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Figure 16. Typical Voltage Ratings for Transformer-Type Indicating Lights

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Figure 17. Push-To-Test Indicating Light

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits

Figure 18. Typical Control Relays

Saudi Aramco DeskTop Standards

Electrical Motor Starter Control Circuits