1. Motor Starting Technologies
Jack Smith – SYD
Joe Pickell - RA
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

2. Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
Objective
Review the basic motor starting technologies:
Across the line
Reduced voltage
Variable frequency
Understand the selection criteria for each technology
Review application considerations for each starting technology
Relative cost
Effects on available torque
Maintenance issues
Reliability
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

3. Across The Line Starters
Electromechanical or Solid State switch that closes the motor power circuit.
Motor is either on or off
Various design standards exist for contactors
NEMA
IEC
Definite Purpose
Characteristics
Motor has full voltage available as soon as power circuit closes
Pulls an inrush current 5-7X Normal running current
Motor can produce full torque immediately
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

4. Across the Line Starter - NEMA
Advantages
Available up to NEMA size 9, 2250A
Simple design, few moving parts, reliable
Proven durability
Versions tested for various applications
Field serviceable
UL and CSA approved
Allen Bradley tested to 10 million operations
Limitations
Not touch safe
Physically large
Panel must be drilled and tapped to mount
Cannot be mounted significantly off vertical
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5. Across the Line Starter - IEC
Advantages
Available up to 860A, AC-3
Modular family includes:
Overloads
MSP’s
Mounting Systems/Busbars
Touch safe design
Versions tested for various applications
Space saving designs, mini versions available
DIN rail mounted
Global approvals
Limitations
Life span is application dependent
Typically 1 million operations at rated load
Limited field serviceability
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6. IEC vs. NEMA Cost / Size / Life Comparison
Data NEMA IEC 18 Amp
Description Size 1 AC-3
HP Rating 10HP 10 HP
Life Operations 10 mil 2 mil
List Price $204 $130
Panel Area Required 21.4 in2 7.1 in2
As we just discussed, cost and size are a consideration and so is application life. So what impact do life requirements of the application have on selection? This chart might help clear this up.
Our NEMA and IEC product selections are still the same for the 10HP, 460V motor application.
As we see, the 460V, 10HP selection criteria for the NEMA contactor calls for a Size 1, 27 amp device and the IEC version, an 18 amp device. Test data on the NEMA contactor specifies a life of 10 million operations and the IEC life/load curves indicate contactor life of 2 million operations.
Notice the list price. The NEMA contactor is $ and the IEC contactor is $ We had already concluded that the IEC solution was less costly when horsepower and voltage was the only consideration.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

7. Life Comparison Equalizing Life
Data NEMA IEC 18 A IEC 38 A
Description Size 1 AC-3 AC-3
HP Rating 10HP 10 HP 25HP
Life Operations 10 mil 2 mil 10 mil
List Price $204 $130 $210
Panel Area Required 21.4 in2 7.1 in2 14 in2
Now, let’s suppose starter life was important.
If 10 million operations were required for the application the choice would have to be a 38 amp IEC contactor at $210.00; now the IEC cost savings is eliminated.
Given that “cost advantage” is no longer in favor of an IEC solution, the advantage is not all lost if panel space is a consideration. The IEC solution can also reflect in cost savings by reducing panel space.
Back to our example. The NEMA size 1 uses 21.4 square inches, while its 10HP IEC counterpart utilizes 7.1 square inches. Quite a savings in panel space. Our 38 amp IEC contactor, which costs the same as the NEMA size 1, is 1/3 smaller with only 14 square inches of panel space required.
As we said, selection criteria is important.
What does your customer require? Ask!
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

8. Across the Line Starter – Definite Purpose
Advantages
Available up to 90A, 1,2or 3 pole versions
Specially tested to HVAC standards
Fast-on connections
DIN rail mounting available
Economically priced approx. 2/3 IEC $
UL and CSA approvals
Limitations
Life span is application dependent
Panel normally drilled and tapped
Very limited field serviceability
No matching overloads
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9. Across the Line Starter – Solid State
Advantages
Available up to 50A, AC-1 or 15A, AC-3
No moving parts
Touch safe design
Ideal for high duty cycle or high vibration applications
Ideal replacement for mercury contactors
DIN rail mounted
Global approvals
Limitations
Heat dissipation can be an issue
No field serviceable parts
No matching overloads
No aux contacts
Approx 1.5x IEC $
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

10. Across the Line Starter – Vacuum
Advantages
Available up to 480 VAC, 600A
Long contact life due to vacuum
Ideal for high duty cycle applications
UL, CSA approvals
Limitations
Physical size may be an issue
Approx. 2x IEC $
Limited offering starting at 200A
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

11. Overload Relays for ATL Starters
Overload Protection
Overload Protection
Our objective is to learn about overload protection: The Why it is needed and How it is achieved through the use of overload protection offered by Rockwell Automation.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

12. Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
Comply with NEC/CEC
Motor running overcurrent protection
NEC article part C
CEC rule
Reduce fire hazard
In the U.S. the user must comply with the National Electrical Code Article 430.
Article 430 spells out minimum safety standards for the proper installation of a motor. Further, Article calls for a “Motor Running Overload Device” and must be used with the proper heater elements. Overloads result from overheating of the motor or short circuits.
NEC Article requires that overload relays are needed to prevent motors from being overheated by being worked in excess of their ratings. In other words, reduce fire hazard. There are other good reasons, also.
We see the circuit as taken from Article 430 and you will notice that Part C applies to the motor running overload device.
We will talk only on the subject of Overload Protection which involves motor overcurrents up to 6 times FLC and not Short Circuit Protection, which is well in excess of that figure.
There are other good reasons, also.
NEC Article 430
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13. Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
Eutectic Alloy Type
Adjust trip setting by installing various rated heater elements
Manual Reset only
In designing the 509 starter, we spent considerable time on the overload relays. The 592 standard and compact, eutectic overload relay and type W heater elements are an important advance in the art of motor protection. The 592’s, just as the contactors, are exceptionally reliable and flexible.
Superior motor protection is just one of the reasons that customers buy our controls. Direct bus bar connection of the standard 592 overload relay to the load side of the contactor improves reliability and maintains the compact design of the 509 starter. Straight through wiring is easily attained with this design.
Type W Heater Elements
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14. Type W Heater Elements Thermal Memory Eutectic Alloy
Resistance Element
Type W Heater Elements
Thermal Mass
To Power
To Motor
This is the construction of a typical Type W heater element. You will note; the 2 main line/load connections; the thermal mass; the resistance material and the all important eutectic alloy. At the bottom of the element you will see the ratchet and pawl assembly. At this point, notice how there is direct contact with the resistance material and the spindle. The Heater Element is intended to be a thermal model of the motor. Its thermal mass stores the heat generated by the current drawn at start and during running, and is designed to follow the heating curve of the motor insulation during running.
This is called “Thermal Memory”.
Pawl to Mechanism Which Controls Relay Contacts
Thermal Memory
Ratchet Stud
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15. Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
Eutectic Alloy Overload Relay Operation
EUTECTIC ALLOY
HEATER
PAWL
RATCHET
PIVOT
CONTACT
ACTUATOR
CONTROL
CIRCUIT TO
STARTER
COIL
POWER
POWER
CIRCUIT
CONTROL TO
STARTER
COIL
Shown in this diagram is the free wheeling ratchet design of the eutectic alloy overload relay. Note that if any of the elements changes state the overload relay trips, thus allowing for trouble free single phase operation. Plus by having replaceable heater elements the starter is in essence programmed for the application and not easily misadjusted in application.
Reset Position
Tripped Position
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Bi-Metal Theory
Bi Metallic
Two metals with dissimilar expansion
Generated heating causes deflection
Adjustable trip setting
Manual or automatic reset
The basic theory of the bi-metal type overload relays is that there are two metals bonded together to form a strip. These metals have dissimilar coefficients of expansion and when heated will bend. (IEC design) As we see on the left, the unit has an integral heater element wound around the bi-metal strip. When current is applied to the load terminals, the element heats up and the bi-metal also heats up. With the generated heat causes the metal with the greater expansion to deflect toward the operator and changes state of the contacts. This is similar to the operation of the Bulletin 193. (IEC design)
The view on the right is the same, with the exception that the heater is interchangeable and replaceable. This is similar to the operation of the Bulletin 592 family. (NEMA design)
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

17. Basic Electronic Overload
Advantages
Increased accuracy
Enhanced performance
Easy to select and apply
Greater application flexibility
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Product Overview
Feature Overview
Insert Molded
Power Stabs
Latching Mechanism
Test Button
Reset Button
Mechanical Trip
Actuator
DIP Switches
(193-EE, 592-EE only)
Trip Status
Indicator
FLA Setting Dial
Control Terminals
95 & 96 / 97 & 98
Load Terminations
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19. Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
Product Overview
Wide 5:1 Adjustment Range
Application flexibility
Simplified product selection with a minimized number of catalog devices, greater overlap
One device covers the range of 4 bimetallic overloads or 19 eutectic heater elements
E1 Plus
Bimetal
0.1A
90A
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

20. Proper Overload Protection vs. Motor Life
Let’s look at the Rockwell Automation “Horse Chart”. This shows, not only the work attempted by the motor, but the results of incorrect element selection as required for the Bul 509 starter. We will show you how to properly select elements later in the session. The correct element shows a happy horse. One element too large can reduce the motor life by 1/3. An element 2 sizes too large can reduce the motor life by 1/9 and 3 sizes too large can result in a “Dead Horse”. The motor life is who knows?
Remember, just mounting elements 1, 2 or 3 sizes too large, or improperly selected or mis-adjusted IEC bimetallic overload device, doesn’t “kill” our horse… it’s the higher levels of current allowed to be drawn by the motor before the heater elements melt or the bi-metallic elements operate the overload relay. Over time, that is what “kills” a motor.
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

21. Reduced Voltage Starters
Basic Functionality
Reduce inrush current during motor start
After start motor runs at full rated speed
Reduced starting torque = reduced mechanical wear
May provide energy savings if peak charges are an issue
Electromechanical
Part Winding
Used with special motors with parallel windings
Reduced starting torque
Wye – Delta
Used with 6 lead delta wound motors
Autotransformer
Reduced starting torque vs. ATL but most per amp of above
Solid State
Uses SCR’s to chop voltage peaks during start up
Electronic controls on SCR’s enable flexible starting profiles
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

22. Economy Solid State Soft Starts
Advantages
Up to 135A
Start ramp time selectable from 2 – 30 sec
Initial torque can be selected from 15% to 65%
Kick start can be selected to provide breakaway torque
Built in Overload protection
Diagnostics via flashing LED
Remote status via alarm contact
Ramp to stop
Limitations
No field serviceable parts
Limited starting torque
4 – 10 starts per hour
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23. Full Featured Solid State Soft Starts
Advantages
Up to 480VAC, 480A
Programmable ramp time
Special pump control algorithm available
Preset slow speed capable
Can do full voltage start
Built in Electronic Overload protection
Diagnostics via local message display or comms
Remote status via alarm contacts or comms
Smart motor braking optional;
Limitations
Limited starting torque
SMC-Flex
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

24. Variable Frequency Drives
Basic Functionality
Offers total speed control including ramp up and down
Speed controlled by changing frequency of power to motor
Speed control may result in energy savings
Component class drives
Power Flex 4
Power Flex 40
Power Flex 400
Architecture Class Drives
Power Flex 70
Power Flex 700
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25. “Component Class” Drives
Optimized for machine-level and stand-alone control
Most economical Allen-Bradley offering in its power, performance & feature segment
Simple selection, set-up, & operation
Industry-standard RS-485 communications capabilities
Industry-standard power structure features & installation options
“4-Class”
Products
Performance / Functionality
PowerFlex 40
PowerFlex 400
PowerFlex 4 5 10 20 50
100
200
Power Rating 460V)
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Component Drive Applications
Provides a smooth accel/decel – no jerky motion
Fixed acceleration using variable frequency
Important when synchronizing machines or processes
Speed changes “on the fly”
Communication status across network
Critical stopping criteria –
For repeatable and accurate “in position” applications
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

27. Rockwell Automation Strengths
The most simple to use product in its class
Integral keypad with control keys and local pot active out of the box
DIN rail mounting, small package size, Zero Stacking
Same integral keypad as PowerFlex 4
Expanded I/O, sensorless vector control, add on communications options and timer/counter/Step Logic functionality
PowerFlex 400 is the HVAC drive with standard features aimed at the centrifugal pump and fan marketplace
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28. Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
Integral LED Keypad Simplifies Start Up
4 digit LED display indicates parameter number or value
LED indicators for run and direction status
LED indicators for units of parameter values
Programming keys similar to all other PowerFlex products
Three simple programming groups
Display Group
Basic Group
Advanced Group
Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

29. Drive Commissioning Made Simple
Just hook up your power wiring and control the drive from the integral keypad
Control keys are active allowing out of the box operation. Status indicators above start key and speed pot indicate when active.
10 most common application parameters contained in Basic Program Group to simplify programming
P031 Motor Nameplate Voltage
P032 Motor Nameplate Frequency
P033 Motor Overload Current
P034 Minimum Frequency
P035 Maximum Frequency
P036 Start Source
P037 Stop Mode
P038 Speed Reference
P039 Accel Time 1
P040 Decel Time 1
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30. PowerFlex 40 – Increased Performance
Excellent motor control, thru 7.5 kW / 15 HP
V/Hz or Sensorless Vector (SVC) modes
Communication
Integral RS485 serial communication
Add-on communication adapters
Expanded I/O
Analog output
2 digital outputs
Logic Functions
Timer
Counter
StepLogic
Similar to PowerFlex4
Common parameter structure & set-up
Integral user interface
Common “4 Class” accessories
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31. Relative Cost Comparison 5-50HP
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32. Relative Cost Comparison 75 – 200HP
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33. Copyright © 2005 Rockwell Automation, Inc. All rights reserved.
Thank You
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34. Copyright © 2005 Rockwell Automation, Inc. All rights reserved.