Korndrfer autotransformer starter

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Korndorfer starter with motor (M), autotransformer (AT) and three switches (1, 2, 3)

In electrical engineering, the Korndorfer starter is a technique used for reduced voltage soft
starting of induction motors. The circuit uses a three-phase autotransformer and three three-phase
switches. This motor starting method has been updated and improved by Hilton Raymond Bacon[1]
Contents
[hide]

1 Operation
2 Advantages
3 Drawbacks
4 History
o 4.1 Description of the Korndrfer patent 1,096,922
5 Uses and styles
6 Medium voltage starters
7 Controlled switching for reducing motor current surge
8 References

Operation[edit]
The Korndorfer starter can be used manually. Newer devices provide full automatic operation, which
in addition would have: triple-pole line contactor (switch), start contactor, running contactor, three
single-pole overload relays, autotransformer with a set tap-changing links, a suitable timer,
and start and stop pushbuttons.[2]
If all switches are open the motor is completely disconnected from the three-phase network.
To start the motor. first the switches 1 and 2 are closed. This supplies the motor a lower voltage from
the autotransformer. The lower voltage limits the input current to the initially stationary motor, which
accelerates. The torque of the motor is also lowered.
The motor continues to increase its speed until the motor torque and the load torque balance each
other and a steady speed it achieved. At this stage switch 2 is opened and momentarily the motor is
supplied by even lower voltage, because the windings of the autotransformer act as inductors

connected in series with motor. This time is short - just enough to disconnect the switch 2 and
engage switch 3, which connects the full voltage to the motor. Further increase in speed begins and
motor reaches its full rated speed.
At this point the "soft start" is ended and motor can work under full load. The autotransformer is no
loger required and is de-energized by opening switch 1 . The motor is supplied directly from the
three-phase network. To stop the motor, switch 3 is opened.

Advantages[edit]
The Korndorfer starter limits significantly the inrush current. It is used for large motors, in which start
by direct connection to the network is not possible. For large motors also thestar-delta starter cannot
be used, especially if they are started with a significant load.
The circuit has advantage over starting with a regular autotransformer, which needs to be at some
point completely disconnected during the start inducing high voltage impulses, which can damage
the electrical insulation of the stator.
The most effective ratio of the autotransformer is between 65-80%.[3]

Drawbacks[edit]
The circuit is quite complex and involves relatively expensive autotransformer. Due to the physical
size of the whole device it might not be possible to add the Korndorfer starter to an existing machine
if space is scarce.

History[edit]
The reduced voltage autotransformer starter or Korndorfer starter[4] was invented in 1908, by Max
Korndrfer of Berlin. He filed the application with the U.S. Patent office in May 1908 and was granted
the patent US 1,096,922 in May 1914. Max Korndrfer assigned his patent to the General Electric
Company.
An induction motor draws very high starting current during its acceleration to full rated speed,
typically 6 to 10 times the full load current. Reduced starting current is desirable where the electrical
grid is not of sufficient capacity, or where the driven load cannot withstand high starting torque. One
basic method to reduce the starting current is with a reduced voltage autotransformer with taps at
50%, 65% and 80% of the applied line voltage; once the motor is started the autotransformer is
switched out of circuit.

Description of the Korndrfer patent 1,096,922[edit]

Max Korndrfer claimed four methods of using an autotransformer for reduced voltage motor
starting. Three of the methods are not used by the industry and it is the 4th method of starting that
has been in use for more than a hundred years
The fourth method is with the star switch closed and as the motor accelerates a change over is
made from the reduced voltage tap on the autotransformer to direct-on-line.

The starting sequence is :

The Star switch is closed

The Start switch is closed to energise the autotransformer
The motor is connected at a selected reduced voltage tap on the autotransformer and starts to
turn and accelerate
After a predetermined period the Star switch will open
After a mili-second delay the Run switch will close, connecting full line voltage to the motor
The Start switch will then open and the motor will be at operational speed

Since 1920, the autotransformer starter has been the most popular device for reducing the starting
current inrush for induction motors; it provides maximum starting torque with minimum line current.
Table 1 - Starting Torque /Current with 3 Reduced Voltage taps
Voltage 50%tap 65%tap 80%tap

Torque 25%

42%

64%

Current 50%

65%

80%

Manufactures offer their reduced voltage autotransformer in two configurations, with a 2 coil
construction or with a 3 coil construction, figures 2 and 3.

Each apparatus has reduced voltage taps at 50%, 65% and 80% based upon National Electrical
Manufacturers Association recommendations.
The phase coils are traditional wound in a single coil assembly with the 0 to 50% winding section
buried below the 50% to 100% windings in a single thermal mass as shown in figures 2 and 3

Figure 4. 3 Coil Assembly

Figure 4 shows an improved 1000 kW 11,000 Volt motor starter autotransformer with

Axial cooling fans,

Cast resin encapsulated coils,
A plurality of windings providing a means of connection as a central switching apparatus,
9 starting voltage tap connections allowing for 5% variation of starting torque
around NEMA recommended taps at 50%, 65% and 80%. This allows the selection of motor

starting torque to be closely matched with the driven load requirements. Selection is by means
of the connection links between the winding sections.
Table 2 - Starting Torque /Current with 9 Reduced Voltage Connections
Voltage 45% 50% 55% 60% 65% 70% 75% 80% 85%

Torque 20% 25% 30% 36% 42% 49% 56% 64% 72%

Current 45% 50% 55% 60% 65% 70% 75% 80% 85%
The thermal dissipation of the first starting stage is maximised by being a physically separated
winding from the windings of the second starting step to full line voltage.

Uses and styles[edit]

The Autotransformer motor starting apparatus is relatively simple compared to solid-state variable
frequency drives. Since it does not contain any power electronics devices, the output waveform is a
sine wave with no additional harmonic distortion or switching waveforms.No special shielding or
cable length limitations are created. Cooling requirements are similar to those of a transformer or
switchgear. The reduced-voltage starter provides the maximum torque with a minimum of line
current.

Medium voltage starters[edit]

The low voltage (<600V) Korndrfer motor starter is a proven workhorse over the years. However
large medium/ high voltage motor starters have reported random autotransformer failures.[5] The
IEEE article by Dr.S.E.A. Emam & Pro.Dr.A.H. Amer of the Engineering Consulting Centre at Ain
Shams University reports on some investigations made for a petroleum company on a 5,400 kW
motor, without a clear reason for the failure. In their article they reported that Siemens was called in
as a consultant and their solution was to fit R-C suppression /surge arrestors similar to that used in
other motor starter failures at a Venezuela pumping station.[6] An article in the Wrtsil technical
journal 01.2009, reports that the four 2,900 kW thrusters motor autotransformers starters on Q4000
a multipurpose oil drill vessel suffered repeated autotransformer failures prior to 2008. Transformer
manufacturers, switchgear manufacture and a European design organization could not give a clear
reason for the failures. All auto-transformer six 3000 kW starters were replaced by variable speed
electronic drives in 2008.[7]
The open transition control scheme disconnects the motor from the power source causing the
motor to slow down and get out of sync with the power phase, once reconnected, mechanical and
electrical transients may damage the motor or its drive train.[8]
Even with closed transition there is a transient produced at contact separation of the Star point
switch. The transient is of a very short duration, less than 5 microseconds and occurs when the
motor current from the secondary of the autotransformer is forced to the line voltage. This is a very
fast event and is the origin of the destructive voltage transients that have caused major breakdowns
of large medium and high voltage starters >1000 kW.

Figure 5

Michael Faraday D.C.L, F.R.S, in 1831 published a paper on his discovery of electromagnetic
induction which is the time rate of change of the magnetic flux with a coil induces a voltage in that
coil, the amplitude of the induced voltage is proportional to the velocity of flux linkages with the coil.
With normal operation a step-up autotransformer would have flux linkages at the supply frequency;
in the case of a very fast dv/dt at the instant of contact separation, the voltage induced into the
redundant windings of the first starting stage, will be extremely large. This basic principle explains
the source of the destructive transient voltage in the Korndrfer motor starter apparatus.
A further transient problem is that with a single coil construction and a star switch, the
autotransformer acts as a step-up transformer during the <5 microsecond period at contact
separation of the Star point switch. With the motor connected to the 80% voltage tap there will be an
escalation of the transient by 5:1 ratio.

The low voltage Korndrfer autotransformer motor starter <600 volts is also subject to a similar
voltage transient with a fast rise wave front, however with a lower operating voltage and state of the
art insulation materials in use may be a factor that contributes to its longevity.
To reduce the risk of any voltage surge it is desirable to replace the Korndrfer motor starter circuit
with an autotransformer that has a central switch circuit that disconnects redundant windings of the
first starting stage from the circuit at the transition, thereby preventing any step-up transformer
connection and voltage escalation.

The root cause of destructive transients in Korndrfer starters, it is random switching of the
changeover of motor current. The uncontrolled timing of the changeover allows the peak motor
current to be switched at any point on the wave. Figure 5 shows the changeover at 90 degrees. This
is a worst-case scenario, peak current at changeover, creates a very high and fast transient. The
central switch circuit prevents voltage escalation, as discussed above. It is therefore desirable to
control the point on the wave at which to switch, the ideal point is when the motor amperes to the
lowest value in all the active windings of the autotransformer.

A 3-coil autotransformer requires a 3 pole switch to control 3 phase voltages, an examination of

figure 9 shows three sine waves displaced at 120 degree intervals. There appears there is no real
point on the cycle where all three phases can be switched simultaneously at any equal low motor
amperage without resorting to complex staggered switching

methods.

(Left)Figure 9.-3 phase power sine curves (Right)Figure 10. 3-coil Schematic

(Left)Figure11. 2-Coil 2 Phase Sine Curves (Right)Figure 12. 2-Coil Schematic

A 2-coil autotransformer has only two windings that are required to be switched at transition. Figure
11 shows the motor current curves for a 2-coil autotransformer. Line 2 is not switched. This topology
is suitable for controlled switching.
An inspection of the sine curves shows that at 30 degrees and 210 degrees, both motor currents are
at the same value and are in the same phase quadrant. Therefore the magnetic core flux in first leg
of the transformer is the same as the magnetic core flux in the third leg, the centre leg has no
windings and its magnetic flux is of no interest.At 30 degrees the amplitude of the motor currents
supplied by the autotransformer are only half the peak motor current that occurs at 90
degrees.(sine30 = 0.5) see Figure 8.
The central switch therefore prevents any step-up autotransformer connection and a practicable
means of controlling the switching transient to a lower value than the star connected switch.
The important points for controlled central switching are:

The central switch is closed before the motor has power supplied,
There is no break in motor current, only a transfer of current,
A synchronized, controlled opening of the central switch.
Synchronized by means of zero crossing of the motor current waveform.

The central switch may be an electromechanical switch or an electronic device using IGBT, EMT or
other similar solid-state devices.

The electronic central switch has only to open its circuit forcing the motor current to transfer into the
80% winding in a no-break, closed transition action. It can provide frictionless, accurate and instant
switching actions that are necessary to operate the changeover point at 30 degrees.
A method of detecting current zero crossing is required to provide the timing measurement for
controlled switching. A current to voltage transformer is used for accurate triggering of such a timing
signal for a controlled switch opening.
Electromechanical central switch has to be carefully selected as it has inherent operating times both
opening and closing. It has to have a stored-energy mechanism and a DC operated release solenoid
for a controllable open command signal. Detection of the motor current zero crossing may be
obtained from a current transformer/resistor voltage sensing circuit, not a voltage crossing. The use
of electromechanical contactors is not recommended for a central switch as their switch opening
speed consistency is subjected to the voltage applied to the hold-in coil. During a motor start the line
voltage drop will fluctuate and the magnetic flux in the hold-in device will also vary, causing
deviations in opening times.

Controlled switching for reducing motor current surge[edit]

The change in motor starting current from the reduced voltage stage can be minimised by switching
at transition to a primary reactor second starting stage. In his patent Max Korndrfer shows an
external reactor coil method "so as to make the gradation in voltage between steps" before a
changeover to direct-on-line.

The external reactor coil method for a second starting stage has merit, as the voltage to the motor is
a function of the motor current taken from the line. It can be seen that during a second stage with a
series reactor, that during acceleration the motor voltage will rise as the line current drops. This
relationship results in greater acceleration energy to a higher motor speed and less disturbance at
changeover to full line voltage.

General Electric engineers [9][10] attempted to improve Korndrfer Methods but neither methods
proposed were successful.