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

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.

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.

Across the Line Starter - NEMA Advantages Available up to NEMA size 9, 1600HP @480VAC, 2250A Simple design, few moving parts, reliable Proven durability Versions tested for various applications Field serviceable UL and CSA approved Allen Bradley tested to 10 million operations Limitations Not touch safe Physically large Panel must be drilled and tapped to mount Cannot be mounted significantly off vertical Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

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 Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

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 $204.00 and the IEC contactor is $130.00. 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.

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.

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 Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

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.

Across the Line Starter – Vacuum Advantages Available up to 500HP @ 480 VAC, 600A Long contact life due to vacuum Ideal for high duty cycle applications UL, CSA approvals Limitations Physical size may be an issue Approx. 2x IEC $ Limited offering starting at 200A Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

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.

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. Comply with NEC/CEC Motor running overcurrent protection NEC article 430 - part C CEC rule 28-200 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 430-32 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 430-32 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 Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

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 Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

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 Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

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 Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 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.

Basic Electronic Overload Advantages Increased accuracy Enhanced performance Easy to select and apply Greater application flexibility Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 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 Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

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.

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.

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.

Economy Solid State Soft Starts Advantages Up to 100HP @480VAc, 135A Start ramp time selectable from 2 – 30 sec Initial torque can be selected from 15% to 65% Kick start can be selected to provide breakaway torque Built in Overload protection Diagnostics via flashing LED Remote status via alarm contact Ramp to stop Limitations No field serviceable parts Limited starting torque 4 – 10 starts per hour Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Full Featured Solid State Soft Starts Advantages Up to 400HP @ 480VAC, 480A Programmable ramp time Special pump control algorithm available Preset slow speed capable Can do full voltage start Built in Electronic Overload protection Diagnostics via local message display or comms Remote status via alarm contacts or comms Smart motor braking optional; Limitations Limited starting torque SMC-Flex Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

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 Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

“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 (HP @ 460V) Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 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.

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 Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

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.

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 Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

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 Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Relative Cost Comparison 5-50HP Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Relative Cost Comparison 75 – 200HP Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. Thank You Copyright © 2005 Rockwell Automation, Inc. All rights reserved.

Copyright © 2005 Rockwell Automation, Inc. All rights reserved.