Performing Installation of Motor Controller System

LO1: Plan and prepare for motor controller

Installation
LO2: Request materials, tools and equipment
LO3: Inspect electrical materials and tools
LO4: Assemble electrical motor controller
LO5: Notify completion of work
LO6: Clean up
Cont……
Electric motor is the electro-mechanical
machine which converts the electrical energy
into mechanical energy. In other words, the
devices which produce rotational force is
known as the motor.
The working principle of the electric motor
mainly depends on the interaction of
magnetic and electric field.
two types of electric motor
 AC motor
 DC motor.

The AC motor converts the alternating current

into mechanical power.
 DC Motor

A machine that converts the DC electrical

power into mechanical power is known as DC
motor. Its work depends on the basic principle
that when a current carrying conductor is
placed in a magnetic field, then a force
exerted on it, and torque develops.
two types of DC motor
 self-excited motor and
 separately excited.
 1. Separately Excited Motor
The motor in which the DC winding is excited
by the separate DC source is known as the
separately excited dc motor. With the help of
the separate source, the armature winding of
the motor is energized and produce flux.
2. Self-Excited Motor
By the connection of field winding the Self-
excited DC motor is further classified into
three types.
 the series motor,
 shunt motor and
 compound wound DC motor.
Cont….
1.Shunt Motor – The motor in which field
winding is placed parallel with the armature,
such type of motor is known as shunt motor.

2.Series Motor – In this motor the field

winding is connected in series with the
armature of the motor.
Cont…
3.Compound Wound Motor – The DC motor
which has both the parallel and series
connection of the field winding is known as the
compound wound rotor. The compound wound
motor is further categorized into short-shunt
and long-shunt motor.
Cont….
A. Short Shunt Motor – If the shunt field
winding is only parallel to an armature of the
motor and not the series field, then it is known
as the short shunt connection of the motor.
B. Long Shunt Motor – If the shunt field winding
is parallel to both the armature and the series
field winding then the motor is known as the
long shunt motor.
 Apart from the above mention motors,
there are various other types of the special
machine which have additional features
like stepper motor, AC and DC servo motor,
etc.
 AC MOTOR
The AC motor converts the alternating current into
mechanical power.
Three types AC motor
 Induction(ASynchronous) motor
 Synchronous motor
 linear motor

1. Induction Motor
The machine which never runs at synchronous speed is
called the induction or asynchronous motor. This motor
uses electromagnetic induction phenomenon for
transforming the electric power into mechanical power.
According to the construction of rotor are
two types of an induction motor
 squirrel cage induction motor and
 phase wound induction motor.
 Two Types of Induction Motors
 Single phase induction motor
 Three phase induction motor

single-phase induction motor is not self-

starting. When the motor is connected to a
single-phase power supply, the main winding
carries an alternating current. It is logical that
the least expensive, most reduced upkeep sort
engine ought to be utilized most regularly.
These are of different types based on their
way of starting since these are of not self
starting. Those are split phase, shaded pole
and capacitor motors. In these types of motors
the start winding can have a series capacitor
and/or a centrifugal switch.
 Cont…
When the supply voltage is applied, current in the
main winding lags the supply voltage because of the
main winding impedance. And current in the start
winding leads/lags the supply voltage depending on
the starting mechanism impedance. The angel
between the two windings is sufficient phase
difference to provide a rotating magnitude field to
produce a starting torque. The point when the motor
reaches 70% to 80% of synchronous speed, a
centrifugal switch on the motor shaft opens and
disconnects the starting winding.
Cont…
 Applications of Single Phase Induction Motor
These are used in low power applications and
widely used in domestic applications as well as
industrial. And some of those are mentioned
below
 Pumps

 Compressors

 Small fans

 Mixers

 Toys

 High speed vacuum cleaners

 Electric shavers

 Drilling machines
A 3 phase induction motor consists of two
major parts
 Stator
 Rotor

The stator is the static part of the motor. The

main function of the stator is to generate the
rotating magnetic field.
Cont…
The stator of three phase induction motor is
made up of numbers of slots to construct a 3
phase winding circuit which we connect with 3
phase AC source. We arrange the three-phase
winding in such a manner in the slots that they
produce one rotating magnetic field when we
switch on the three-phase AC supply source.
The stator of the motor consists of overlapping
winding offset by an electrical angle of 120o..
When we connect the primary winding, or the
stator to a 3 phase AC source, it establishes
rotating magnetic field which rotates at the
synchronous speed.
The stator of the three phase induction motor consists of three
main parts:

 Stator frame
 Stator core

 Stator winding or field winding

Stator Frame
It is the outer part of the three-phase induction motor. Its
main function is to support the stator core and the field
winding. It acts as a covering and provides protection
and mechanical strength to all the inner parts of the
machine. The frame is either made up of die-cast or
fabricated steel. The frame of three phase induction
motor should be strong and rigid as the air gap length
of three phase induction motor is very small.
Otherwise, rotor will not remain concentric with stator
which will give rise to unbalanced magnetic pull.
 Stator Core
The main function of the stator core is to carry
alternating flux. In order to reduce the
eddy current losses the stator core is
laminated. This laminated type of structure is
made up of stamping which is about 0.4 to 0.5
mm thick. All the stamping are stamped
together to form the stator core, which is then
housed in a stator frame. The stampings are
generally made up of silicon steel, which
reduces the hysteresis loss.
 Stator Winding or Field Winding
The slots on the periphery of stator core of the three
phase induction motor carries three phase windings.
This three phase winding is supplied by three phase
ac supply. The three phases of the winding are
connected either in star or delta depending upon
which type of starting method is used.
The squirrel cage motor is mostly started by star-delta
stator and hence the stator of squirrel cage motor
are delta connected. The slip ring three phase
induction motor are started by inserting resistances
so, the stator winding can be connected either in
star or delta. The winding wound on the stator of
three phase induction motor is also called field
winding and when this winding is excited by three
phase ac supply it produces a
rotating magnetic field.
Cont…
The speed requirement is inversely proportional
to the number of poles, given by the formula:
Ns= 120f/p Where Ns= synchronous speed
f = Frequency p = no. of poles
 slip
Slip ,S, is defined as the difference between synchronous
speed and operating speed, at the same frequency,
expressed in rpm, or in percentage or ratio of
synchronous speed. Thus .
S = ns - nr / ns
Where ns is stator electrical speed, nr is rotor
mechanical speed. Slip, which varies from zero at
synchronous speed and 1 when the rotor is at rest,
determines the motor's torque. Since the short-circuited
rotor windings have small resistance, even a small slip
induces a large current in the rotor and produces
significant torque. At full rated load, slip varies from
more than 5% for small or special purpose motors to less
than 1% for large motors. These speed variations can
cause load-sharing problems when differently sized
motors are mechanically connected. Various methods
are available to reduce slip, VFDs often offering the best
solution.
 Rotor
The rotor is situated inside the core of the
stator.
The rotating part of the motor is known as the
rotor.The field winding induces the constant
magnetic field in the core of the rotor.
The rotor core and the rotor winding are the part
of the rotor. The winding of the rotor is excited
by the DC supply. The squirrel cage and the
phase wound are the types of the rotor.
The core of the squirrel cage rotor is made of the
cylindrical iron core. The core has a semi-circular
slot on their outer surface on which the copper
or aluminum conductors are placed. The
conductors are short-circuited at the ends with
the help of the aluminum or copper rings.
Cont….

Depending upon the type of rotor used the

three-phase induction motor is classified as:
 Squirrel Cage Rotor
 Slip Ring Rotor or Wound Rotor or Phase

Wound Rotor
 Comparison Chart

Basis for Comparison Stator Rotor

Definition It is a stationary part of the machine It is the rotating part of the motor.

Parts Outer frame, stator core and stator winding. Rotor winding and Rotor core

Supply Three-phase Supply DC supply

Winding Arrangement Complex Easy

Insulation Heavy Less

Friction Loss High Low

Cooling Easy Difficult

 Working of Rotor & Stator

The stator generates the rotating magnetic field

because of the three-phase supply. If the rotor
is in the standstill condition, then the
electromagnetic force induces in them because
of the electromagnetic induction phenomena.
The electromagnetic induction is the phenomena
in which the emf induced in the current
carrying conductor because of the variable
magnetic field. The current induces in the rotor
which causes the rotor to move.
 Contactor
A contactor is an electrically controlled switch
used for switching an electrical power circuit,
similar to a relay except with higher current
ratings. A contactor is controlled by a circuit
which has a much lower power level than the
switched circuit.
Cont….
Contactors are used to control electric motors,
lighting, heating, capacitor banks, thermal
evaporators, and other electrical loads.
A contactor has three components. The
contacts are the current carrying part of the
contactor. This includes power contacts,
auxiliary contacts, and contact springs. The
electromagnet (or "coil") provides the driving
force to close the contacts.
 FUSE
 Is protective apparatus with the member of fusible the
opening and closing of directly heated current and
destroyed by the current.
 is a one-shot Device..The heat Produced by over
current. Causes the current carrying. Element to melt
open,. Disconnecting the load from the source voltage
CIRCUIT BREAKER (CB)
 The main circuit breaker contains a bi-metal strip and a
simple electro magnet.
 The current flowing through the bi-metal will heat pre-
determined temperature, the bi-metal bent the bi-
metal.
 When the bi-metal is heated to a the resulting
deflection will trip the MCB. In case of a short circuit or
excessive overload the current flowing in the electro-
magnet will be so high as to produce a magnetic field
strong enough to trip the MCB with out a time delay.
 OVER LOAD RELAY
 Is the effect of an apparatus that operates with
an excessive value of current but necessarily a
short circuit?
 It is built into a protective plastic housing which

contains three bimetallic trips similar to those

built into a motor protection switch.
 They activate a break contact which in turn will

switch off the magnetic coil of the magnetic

contactor.
 Emergency Stop Button
 It has a large, easy to operate, mushroom shaped
actuator.
 This actuator must be mounted on a yellow
background.
 When operated, the actuator latches in the “Off “

position.
 The actuator is released by twisting the mushroom

shaped head.
 TIMER
 is a clock that controls the sequence of an
event
 it used for producing precise time delay
 it used to initiate an action after a known

period of time
 there are two types of timer

1. ON-Delay Timer
2. OFF-Delay Timer
 1. ON- Delay Timer
 When the voltage is applied to the timer coil
the time is start to count. when reached the
setting time the contact becomes closed and
the circuit becomes initiate/ on. when the
voltage is removed the contact of timer
becomes open.
 2. OFF-Delay Timer
when the voltage is applied to the timer coil the
time is start to count automatically the circuit
is initiate/on. when the setting point is reached
the timer contact becomes open and the circuit
becomes OFF.
 RELAY
Relay is a simple electromechanical switch made
up of an electromagnet and a set of contacts.
Relays are found hidden in all sorts of devices. In
fact, some of the first computers ever built used
relays to implement.
Relay Construction Relays are amazingly simple
devices. There are four parts in every relay:
1.The Electromagnet
2.The Armature that is attracted by the electromagnet
3. A Spring
4. A Set of electrical contacts
 Motor Control
There are four major motor control topics or categories to consider
1) Starting the Motor
 Disconnecting Means
 Across the Line Starting
 Reduced Voltage Starting

2) Motor Protection
 Over current Protection
 Overload Protection
 Other Protection (voltage, phase, etc)

3) Stopping the Motor

 Coasting
 Electrical Braking
 Mechanical Braking

4) Motor Operational Control

 Speed Control
 Reversing
 Jogging
 Sequence Control
 Motor Controller

 A motor controller is the actual device that

energizes and de-energizes the circuit to the
motor so that it can start and stop.
 Motor controllers may include some or all of

the following motor control functions: starting,

stopping, over-current protection, overload
protection, reversing, speed changing, jogging,
plugging, sequence control, and pilot light
indication.
 PRACTICAL ACTIVITY ONE

 Full Voltage Magnetic Starting of Three Phase IM

Perform the connection of Full Voltage Magnetic Starter/Contactor for Start Stop Operation,
with indicating pilot light stop, start, and tripping pilot light.
 PRACTICAL ACTIVITY TWO
Perform the connection of Full voltage motor starter with two- stop, two-start push
button switch without indicating lights
 PRACTICAL ACTIVITY THREE

straight line diagram of the control circuit of

three start-stop stations.
Cont…….
Cont…….
Emergency Shut down Unit (ESDU) Full Voltage Across the Line (FVAL) motor
starter with indicating lights.
Cont…
Jogging – is moving a machine with short jobs of power. It is
used to bring a machine into some particular position,
generally for loading and unloading. Jogging is used on
machinery to allow machine set-up, e.g., Conveyor, sewing
machine, printing machine, and others. Regardless of which
method is used, the basic control requirement either is for the
motor starter to energize when the jog button is push and de-
energized when the jog button is released.
Cont….
Three phase induction motor control by Forward and Reversing Full Voltage Across the
Line (FVAL) motor starter with auxiliary contact interlocking and complete indicating
lights.
Cont….
Three phase induction motor control by Forward and Reversing Full Voltage
Across the Line (FVAL) motor starter with pushbutton and auxiliary contact
interlocking, and complete indicating lights.
 Cont….
Three phase induction motor control Limit switch added to automatically control forward
and reverse operation.
Wye-Delta Reduced voltage motor starter, (Momentarily on Timer) with indicating lights of 3 Phase Induction Motor.
 Wye- Delta Starter

This method of reduced- voltage starting applies only to three phase, delta
connected motors. If a delta-connected motor is connected across 230/380
volt. Three phase line, each phase will receive 230 volts. On the other hand, if
the motor is reconnected in wye and same line voltage is applied, each phase
will receive 58 percent of 230v. To apply this principle to a controller, it is
necessary to bring both ends of each phase out of the motor. The six leads can
be interchanged when connecting into wye starting to delta running a
magnetic wye-delta starter of open transition type.
This term refers to the momentary disconnection of the motor from the line during
the period of change over from wye to delta connection. These starters are also
made with closed transition. After the time –delay relay time out, the time
open ( TO ) contacts open, dropping out contactor and timed-closed (TC)
contact close.
The Star Delta Starter is a very common type of starter and is used extensively
as compared to the other type of starting methods of the induction motor. A
star delta is used for a cage motor designed to run normally on the delta
connected stator winding. The connection of a three-phase induction motor
with a star delta starter is shown in the figure below.
 Cont…

When the switch S is in the START position, the stator windings are connected in the star as
shown below.

When the motor picks up the speed, about 80 percent of its rated speed, the switch S is
immediately put into the RUN position. As a result, a stator winding which was in star
connection is changed into DELTA connection now. The delta connection of the stator
winding in shown in the figure below.
 cont…

Firstly, the stator winding is connected in star and then in Delta so that the starting
line current of the motor is reduced to one-third as compared to the starting
current with the windings connected in delta. At the starting of an induction
motor when the windings of the stator are star connected, each stator phase
gets a voltage VL/√3. Here VL is the line voltage.
Since the developed torque is proportional to the square of the voltage applied to
an induction motor. Star delta starter reduces the starting torque to one-third
that is obtained by direct delta starting.
 Cont….

Theory of Star Delta Starter Method of Starting of Induction

Motor
At the starting of the induction motor, stator windings are connected in star and, therefore,
the voltage across each phase winding is equal to 1/√3 times the line voltage.
Let,
VL is the line voltage
Istyp is the starting current per phase with the stator windings connected in star.
Istyl is the starting line current with the stator winding in the star
For star connection, the line current is equal to the phase current
Therefore,
If,

V1 is the phase voltage

VL is the line voltage
IstΔp is the starting current per phase by direct switching with the stator windings connected in delta.
IstΔl is the starting line current by direct switching with the stator windings in the delta.
IscΔp is the short circuit phase current by direct switching with the stator windings in the delta.
Ze10 is the standstill equivalent impedance per phase of the motor, referred to the stator
 Limit switch
Limit switches are devices that convert mechanical motion
or physical position on presence into electrical signal.
Limit switches are incorporated in the motor control circuit.
 Reduced-voltage Starting Control Circuit for Three
Phase Cage Asynchronous Motor
Because the motor that has big capacity has the more starting current, so when we
want to start this kind of motor, we often reduce the voltage of stator to start the
motor. Because the voltage of stator has a direct proportion with the current, so
reducing the voltage can reduce the starting current.
Typical reduced voltage starter types include:
1. Primary Resistance Starters
2. Wye-Delta Starters
3. Autotransformer Starters
4.Part winding starters
Auto-Transformer Reduced voltage (Wye) motor starter, (Momentarily on Timer) with indicating lights
Resistor aided reduced voltage motor starter, (Momentarily on Timer) with indicating lights
Full Voltage Across the Line (FVAL) Cyclic Operation motor starter with indicating lights
Cont…
Primary Resistance close Transition, Reduced voltage
motor starter, (Momentarily on Timer) with indicating
lights
Reversible Wye-Delta motor starter, (Momentarily on Timer) with indicating lights
THE END!!!!!!!!