t76 practical applications of soft starter technology

8/9/2019 T76 Practical Applications of Soft Starter Technology

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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.Rev 0!"C#$00%

Soft Starter TechnologyApplying &'C(s to ma)imi*e investments and energy e++iciency


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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Title:

ractical applications o+ &o+t &tarter technology +or improved per+ormance

and energy management

Description:

Increase your technical competency and understanding o+ the latest &o+t

&tarter technology, and +ind out how &'C-s can e applied to ma)imi*e your

investment and energy e++iciency. /his session will include a rie+ overviewon technology, recent advancements, application e)amples and

considerations, use o+ the &'C Application i*ards, and an overview o+ the

Allen %radley &'C port+olio.

RAOTM - Topic


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Agenda

Allen %radley &'C ort+olio

Application i*ards

Application )amples and Considerations

Recent Advancements

Understand Soft Starter Technology


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AC Motor Control Basics

3

%asic Advanced


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Reduced Voltage Starter Background

re 1$!0(s R4& /ypes Auto /rans+ormer

art inding

ye"5elta 6&tar"5elta7

rimary Resistance

rimary Inductance

ound Rotor

Electromechanical Solid State

/oday(s R4&&olid &tate R4&

4oltage controlled through use o+ &CR(s

6&ilicon Controlled Recti+iers7 8 %ack to %ack &CR(s

&CR triggered 9#:; y energi*ing the


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Solid State Starting Basics

8

A. =sing &CR(s in an 9opposed; 6ack to ack7 con+iguration, the +ull sine wave o+ theAC power can e controlled.

%. %y controlling when an &CR is +ired in the cycle, the output voltage can e

controlled. /he result is sometimes called a :otch.

SCR Control

VIN

SCR

Gate

VOUT

Gate Signal

A B


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Soft Motor Starting Basics

>

Typical Motor Starting Curve

100%0 Speed -%RPM

Starting Torue!"ock rotor torue#

Pull-up torue

Break-do$ntorue

ull loadtorue

ull VoltageStarting Characteristics

Starting Current&'("A

High starting torue can cause damage to the mechanical system!

High current can cause pro"lems in the electrical system

180%

100%


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I+ you reduce voltage y 0?, the result is a >? reduction in motor tor@ue.

(.5)2 = .25 or 25% of LockedRotor Torque

180%

100%

100%0 Percentage of Full Speed

Full Voltage Torque

#hysics of $educed %oltage and Motor Torue

Reduced Voltage Torque

Percentageof Full Rated

Torque


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$

)ample

100%

0 Speed -RPM

T o r q u e

( f t l b )

100

%

72%

25%

'))%

*+)%

,))%

+))% Voltage

*% Voltage

*)% Voltage

Full Load

Torque required

by the load

% F L A

( a m

p )

Current

Torue


10/59Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Reasons for Soft Motor Starting

10

'inimi*e mechanical damage o+ system components and product%elts,


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1lectro.echanical 2s3 Solid State

12

Starti!"

Method

#olta"e Ad$utme!t

Ra!"e

Tra!itio! Reulti!" Torque

Pri.ary

Resistance

i(ed Step0Steps Closed %Current Sd

Auto 4f.r *)0'*0*% Closed 5*065075%

8ye-9elta ,,% Open or Closed ,,%

Solid State ) - +))% Stepless ) - +))%

&olid &tate delivers greater +le)iility Allow +or the starting currentDtor@ue to e optimi*ed versus standard reduced

voltage starter types )ample &tar"5elta reduced voltage starter is +i)ed at 00? currentD? /or@ue

&olid &tate insures minimal amount o+ energy to accelerate motor even i+ the load only

re@uires 2? tor@ue.

&& eliminates transitions due to electromechanical limitations #pen or Closed transitions

#pen disconnects motor +rom line voltage, Closed maintains connection to line %oth cause current surges during start



Ad2antages of Solid State Control

nhanced Control #ptionsE Advanced &tartD&top controlE =ser rogrammaility and settingsE &calale setting +or the critical nature o+ applicationE ocal, 'anual, Automatic 'odes

Inherent 5iagnosticsE Current, 4oltage, ower and nergy 'onitoringDprotectionE Faults and Alarms 6some ased on real time clock7E

Controller vent logs and &napshot 6what happened right e+ore a +ault7

owest Installed Cost with :etwork IntegrationE ase o+ Communication inkage 6i.e. multi protocol, A#(s7E ocali*ed ID# and ControlE ire Reductions

1


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Ad2ances in Starting0Stopping Modes

SMC()* +#atented, -inear Acceleration Starting Mode&implest &tarting 'ode

owest starting current pro+ile per start Regardless o+ loading condition

Ideal +or any applicationrovides control over oth tor@ue and speed

=nmatched motor starting per+ormance

&elected start time closer to actual than any other stating methodH

1


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Starting Perfor.ance : Co.parison

1>

-inear Accel vs! Traditional Soft Start: High 4nertia -oad

#arameter Settings: &tart /imeJ 10 second

Torue #ulse.Mechanical 5ear and Tear

Higher #ea0 Current

Time

& Sec.Div / 23* Sec

& Sec.Div / 26 Sec

Current more sta"le andless disruptive to po1ersystem



SMC Soft Starters

Po$er and 1nergy Manage.ent



Soft Starters and 1nergy Manage.ent

Reduction o+ the peak inrush o+ a motor 6i.e. peak current7 Reduces the peak demand charges

Charges are determined by utility based on the peak energy usage

Advantages o+ Controlled 5emand Allows +or the +acility to optimi*eDma)imi*e distriution

Smaller genset’s or transformers (incl. feeders… wires etc.)

Allows the power company optimi*eDma)imi*e distriution

Possible reduced installation cost based on system demands

&calale er+ormance

&'C Fle) and &'C"0 rovide advanced ower and nergy 'onitoring 'easurement it manage it

4isiility helps provide usiness case support +or +uture process and product improvements


20/59Copyright © 2012 Rockwell Automation, Inc. All rights reserved.20

Agenda


Application i*ards

Application E7amples and Considerations

$ecent Advancements




Motor Starting Co.parison

8ull %oltage 9D-;

Simplest Starting Solution

8ull torue applied to motor 'echanical wear K8) inrush current eak demand charges

imited Functionality =nless used with

advanced #verload

8inite Mechanical -ife Contacts will wear out

SMC Soft Start

&imple Starting and Stopping

-imited Control at various speeds

$educed torue and current during

starting

&imple to adLust and setup

Reduced installation costs &maller +ootprint :o need +or harmonicD'C

mitigation

Bighly e++icient when running at +ull speed nergy &aver er+ormance +or light loads

=p to 1 di++erent starting modes

%8D.Drive

; Complete Continuous Control at any

&peed

; 8ull torue at any speed without

sacri+icing current

; Bighly e++icient motor and application

per+ormance

; 'ore comple) setup and install; arger +ootprint

; Impact on ower Muality; Application Considerations

; 'otors types; ead engths; ire /ype; Amient Conditions



Selecting a Starting Method

&peed Control is re@uired

Consistent Acceleration and 5eceleration (New SMC-50 exception)

Bigh starting tor@ue re@uired Continuous Feedack 6critical position control7

Custom starting and stopping maneuvers

Faster stopping with 5ynamic raking options

5rive can hold rotor at *ero speed =ndersi*ed or closely matched motor or power source

22

When do I specify a drive versus a soft starter?



8hy Reduce 9o$n ti.e

#ro"lem:E %elts, gears and machinery can e damaged y across"the"line starting

SMC: E engthens system li+e y reducing mechanical stress during startingE Reduces 5#: /ime

Belps reduceDeliminate '# on e@uipment

:o need to replace damaged parts 'inimal production loss

2

Breakdown Torque

180%

100%

100%0

Percentageof Fu Load Torque

Percentage of Fu !"eed

#$g torque can cau&e

"'&$ca daage to teecan$ca &'&te.



8hy Reduce 9o$n ti.e

#ro"lem:E ower company restrictions on incoming line current, or you pay the penaltyE eak power lines cannot handle high inrush currents, causing rown outs or e)cessive line

disturances, which in turn cause other processes to shut down

23

00%

100%

100%0

Percentageof Fu Load *urrent

Percentage of Fu !"eed


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Standard Starting Methods

Current -imit rimarily used to limit line disturances Constant or very lightly loaded motor ans> Centrifuge> Ball Mill> 8ashers

Soft Start

rimarily used to limit mechanical stress Constant or e)ponentially increasing loads

Co.pressors> Pu.ps> Con2eyors

Soft Start.Current -imit 1ith loaded con2eyor

8ull %oltage :ot a common &tarting mode.

» DOT1 ull 2oltage reuired to accelerate the .otor .ay e a sign of

other prole.s !i3e3 Enitial Torue of F G)%# =sed as a &olid &tate Contactor +or Bigh cycle rates

28



Standard Starting Methods

#ump Control egacy version o+ tor@ue control optimi*ed +or centri+ugal loads &imple to apply ut some considerations )ponentially increasing load such as Compressors, umps, Conveyors

Torue Control &imilar to ump Control per+ormance ut applicale +or all load types

'ore di++icult to apply ut yields higher level o+ per+ormance

-inear Acceleration.Deceleration &implest starting, lowest current , most consistent starting time per start regardless o+ load

2>



HPu.p ControlI in SMC-le( J SMC-*)

Designed for Centrifugal #umps Applications lightly loaded at *ero speed Reduces surges 6water hammer7 caused y uncontrolled acceleration and deceleration Can eliminate the need +or speciali*ed +low control valves ase o+ pump con+iguration rovides control without the use o+ sensors or +eedack devices

9ump Control; Compared to inear Acceleration :o advantage, other than legacy migration

9ump Control; Compared to /or@ue Control asier to set up and optimi*ed +or centri+ugal pumps

=ot intended for #ositive Displacement #umps Full oad re@uired at *ero speed 4ariale &peed typically re@uired to control +low

2!


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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.2$

Torque

Speed

Pump System

ull Spee!

"O#Sta$t

ull#a!

SMC-le( J *) Pu.p Control

S&t Sta$t

Pump Sta$t

%&'e

e!er"y(po)er

SMBO S t M t B ki


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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.0

SMBO S.art Motor Braking

SMC le( and SMC-*)

/he &'%O &mart 'otor %raking is designed to stop a motor @uickly :o additional hardware or +eedack devices are re@uired

Automatic *ero speed shut o++ is integrated into the controller

SMBO S t M t B ki


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SMBO S.art Motor Braking

SMC le( and SMC-*) Considerations

Bow +ast do you want to rakeN $ule of thum"J It will take you at least 1. times as long to rake a

motor as it will to start 6 to 3 times is more typical7

Bow much power can you use +or rakingN $ule of thum"J Anything more than aout 00? can play havoc with

power systems and cause nuisance tripping or worse.

Can the power system handle the demands o+ raking current +or the

entire duration o+ the stopN

Bow consistent does the rake time need to eN A good power supply is critical to consistent raking

1

>ood line %oltage regulation is the 0ey to successful "ra0ing?


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SMBO Co..on Concerns0Kuestions

%raking is hard on the motorN

rue, %rakingP regardless o+ the method, is hard on the motor windings

:oise is common during rakingN

rue, moans and groans o+ all kinds can e heard in a motor during raking

%raking produces increased Barmonic distortionN

rue, the &'C produces some harmonic distortion during starting and stopping, however thelevels are insigni+icant 6typically Q 10? o+ the +undamental7

&'% is a good alternative +or Critical rakingN

!a"se, &'% is not intended to e used +or "&top scenarios. /o many variales are involved

which can alter the per+ormance o+ this +eature

/he &'% option damages motorsN !a"se, %raking is hard, ut we can not create more energy then what the motor demands.

'otor damage is typically caused y incorrect settings or normal wear and tear

&mart 'otor %raking is an e)act scienceN

!a"se, 'ost applications are dialed in via trial and error

SMC


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SMC

Special Application Considerations

'ulti"'otor Applications 'echanically Coupled 6/ransmission, direct gear drive, Conveyors7

&ingle &'C +or multiple motors &eparate #verload protection re@uired

:ot 'echanically Coupled 6:o physical connection7 &eparate &'C(s per motor #ne &'C :ot Recommended

Reduced Perfor.ance and adLustaility Too .uch 2ariaility in .otor characteristics Cost ad2antage $ith AdL3re3 9ri2e> ut less $ith SMC

SMC


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SMC


ower &ource &i*ing


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SMC


ower Factor Correction Capacitors ine side only " locating load side can damage the &CR Ideally FCC are rought in with up"to"speed contact #yna$ic Correction can e responsile +or nuisance line +ault(s

/ransientDCyclic &pikes o+ Current 5ue to oad 4ariation )amplesJ Rock Crushers, ood Chippers, %and &aws, etc. ith the SMC(8le7 @ SMC(', &pikes 120? o+ controller ma) +rame rating causes the ypass

to drop in and outP:#/J I+ this is happening a lot, the &'C is likely under si*ed +or the application

Insure the FA adLustmentDprogramming is correct +or the motor operation &'C" and &o+t &top For est operation try to si*e &'C" mid range per &election


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Si/ing the starter for the application

&election guides are correct +or $0? o+ applications 6umps, Fans, Compressors7 &imply choose ased on voltage, horsepower, current and insure that the motor FA+its the &'Cs operating range

10? o+ applications may re@uire a closer look

%pp"ication %na"ysis& oad with potential high starting inertia or minimal load Flywheel, chippers, grinders, raking, retro+its, running vs. starting re@. etc.

her$a" %na"ysis may e re@uired to determine proper si*e +or the +ollowingJ

)tended starting or stopping times 60 sec7 Aggressive 5uty Cycle 6 10 timesDhr7

#peration in elevated 6aove 0C7 amient temperatures

RA 800? 6i.e. Bigh e++iciency motors, :'A 5esign A7

Solution to Assist: SMC +Estimation 5iard,


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Copyright © 2012 Rockwell Automation, Inc. All rights reserved.>

Agenda


Application 5iards

Application E7amples and Considerations

$ecent Advancements



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SMC Application 8i/ards

/o provide a etter Estimation to the applicaility o+ a &'C", &'C Fle) and &'C"0 product to a given set o+ motor S load operating re@uirements.

Why use the Wizards (eTools)?


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SMC Application eTool’s

Thermal 5iard =sed +or simpleD@uick analysis o+ &'C

capailities +rom a thermal perspective

Short Circuit #rotection Device

=sed to guide selection o+ ranchcircuit protection components

i.e. +use or circuit reaker si*e ypass and isolation si*ing

Application 5iard =sed +or advanced modeling o+ the

complete system including &'C

thermal capailities and motorDload

starting characteristics

i*ards Availale +romJ

roposalorks 9/ools; pull"down or +romJhttpJDDa.rockwellautomation.comD'otor"ControlD&o+t"&tartersD&'C"Fle)TDta8


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SMC Application eTool’s

&'C Applications uilt +or moilephones and talets Cross plat+orm support with all

maLor moile operating systems i#&, %lackerry, and Android

B/' ased applications Allows +or ease o+ use and

updating Can run like any standalone

moile application Almost +ully o++line capale

#o an %pp Search for 'ocwe"" %uto$ation


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Solid State Po$er Control Portfolio

SMC ™- 50

P e r f o r . a n c e 0 % u n c t i o n

a l i t y

A.pere Rating !"ine and 9elta#

5* +)) 5)) *)) +'))* )) +)))

SMC ™ Dialog

SMC ™ Flex

SMC ™-3

H5ialog supports line con+iguration only

SSC

Allen Bradley


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Allen-Bradley

SMC Conte.porary Offering

3

SMC(' SMC 8le7 SMC()*

y*rid +ower Structure y*rid +ower Structure So"id State +ower Structure

SMC a.ily


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SMC a.ily

Choosing a Power Platform

Byrid &olid &tate 6Integral %ypass7 2 /hyristors per phase 68 total7 /hermal 'ass &mall &tirring Fans

Integral &horting or 9%ypass; Contactor

/rue &olid &tate 2 /hyristors per phase 68 total7 arger +inned heat sinks S +ans

#ptional e)ternal ypass contactors Aility to replace contactor Aility to si*e contactor AC1 or AC

Hy"rid Solid StateAC)'(B

&maller

/otal Footprint

ess

)ternal iring

#ptimi*ed /hermal'anagement

asy roduct&election

ower /otal

Installed Cost

True Solid StateAC)'(A

Ideal +or Barshnvironmental

Conditions

Bigher &CCRratings

haseRealanceDnergy&aver Capaility

BigheroperationsDhour

&calale /hermalRatings

SMC a.ily


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SMC a.ily

Choosing a Power Platform

Internal %ypass 6&'C", &'C Fle)7

Ideal +or small spaces &mallest total +ootprint

asy selection and application

owest total installed cost

&olid &tate 6&'C"0, &'C 5ialog, &'C lus7

Ideal +or critical per+ormance in

tough environmental conditions

Allows +or &peciali*ed Control

)ternal %ypass o++ers

operational +le)iility and

redundancy

3

y*rid +ower Structure So"id State +ower Structure


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SMC-, O2er2ie$

Compact Series Byrid design 6internal ypass contacts7

&impli+ied 5I and Rotary &et"up

5in Rail 'ountale through ! amps

3 &tartingD&topping 'odes &o+t"start, &o+t"stop, Current imit, ick &tart

%asic 5iagnostics

Compa't dei"! pro*ide + phae 'o!trol, i!'reaed i!telli"e!'e, a!d u!mat'hed

performa!'e Motor a!d ytem dia"!oti' a!d a! ele'tro!i' o*erload )ith ad$utable

trip 'la help redu'e do)!time a!d prote't aet

y*rid +ower Structure


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SMC le( - O2er2ie$

Modular Class

Byrid design 6internal ypass contacts7

%uilt"In C5 and eypad

G Start0Stopping Modes

, slo$-speed .odes S.art Motor Braking

nhanced 5iagnostics and rotection +unctions

y*rid +ower Structure

Modular dei"! feature + phae 'o!trol, ad*a!'ed i!telli"e!'e, performa!'e

a!d dia"!oti', 'ommu!i'atio! fle&ibility, modular 'o!trol module(po)er

module(fa! aembly for a 'ot effe'ti*e pa'.a"e


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SMC-*) Product O2er2ie$

Benefits of a 8ully Solid State #o1er Structure9no integral "ypass;

Improved per+ormance in high viration applications

er+ormance not impacted y environmental deris onger li+e 6no mechanical li+e limits7

&calale thermal ratings

Bigher &CCR ratings 100 a Fuses

8 a %reaker

2


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SMC-*) Modes of Operation

&o+t &tart Current imit wD ick &tart ump Control # 1nhanced2 S"ow Speed& $% to $5%

+atented Sensor-"ess 3inear %cce"eration4

Consistent ramp up time &no tachometer

re'uired( Optimi)es energy consumption

or,ue Contro" Full 4oltage 5ual Ramp wD ick &tart

SMC 8le7 provides -inear Acceleration Start ho1ever it reuires a tachometer for speed feed"ac0

Startin. Modes Stoppin. Specia"ty Modes Coast &o+t &top

&mart 'otor %raking 6&'%7

3inear #ece"eration

1xterna" rain. Contro"

ump Control

Motor Windin. eater

1ner.y Saver hases ack voltage sensing lighter loads

mergency Run

= E 5 ?

= E 5 ?

= E 5 ?

= E 5 ?

= E 5 ?

= E 5 ?



56/59


SMC *) Modes of Operation

!inear Seed

+#atented, Sensor(less -inear Acceleration Starting Mode Accomplished via Advanced 'otor &peed stimation Algorithm

E :o e)ternal +eedack re@uired " reduces cost and potential +or +ailure

E rovides e)acting motor acceleration control under varying load conditions

&implest to &etupE 2 arameters Re@uired to con+igureJ Ramp /ime and Initial /or@ue 6used as re+erence7

E ReducesDeliminates the need +or the 5ual Ramp mode

Always uses the minimum amount o+ energy needed to accelerate the motor in the time re@uested

6regardless o+ the loading condition7

8


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SMC *) Modes of Operation

Comarison #$amle

!

-inear Accel vs! Torue 9#ump; Start: #ump -oad

#arameter Settings: &tart /imeJ 10 secondTime

& Sec.Div/ 3* Sec total

'otor load appro) 8? o+ FA

& Sec.Div/ ) Sec total

Higher #ea0 Current

:#/sJ

" Actual Start time di++erence o+ inear versus tor@ue mode

" Smoother torue curve +or inear versus tor@ue mode" -o1er pea0 current with inear Acceleration mode


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t76 practical applications of soft starter technology

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