MOTOR CONTROLLER

Motor Controller

Motor controller is a one system are consist of combination devices to control the single phase or three phase motor. In others word to protect the motor become safety use. For ac we call as a driver or controller but for ac call as a starter.

Motor Controller Functionality

1. 2.

3.
4. 5.

6.

To start and stop the motor.Single Phase or three phase motor. To avoid the motor starting itself after breakdown. ( No-volt coil or No-volt release concept ) To minimize starting current,such as star delta , autotransformer and rotor resistance starter. To avoid any sparking and burning at the motor. To start the motor step by step or other types of controller such jogging control and rotor resistance starter. Operation the motor are in safety user and far away controller.

Types of starter.
1. 2. 3. 4.

Direct On line starter Star- Delta starter Auto-transformer starter Rotor Resistance starter

Advantages of the Motor Starter

Less

mechanical force to the motor coil. Less mechanical enjakulasi to the motor frame,shaft and transmission in the motor. Motor can rotate step by step depending to the load. Reduce voltage drop to the motor. Reduce any supply system disturbing ecspecially high hp/amp of the motor.

Disadvantages of the Motor Starter

Reduce torque of the motor. High cost to prepared starter component. Need maintenance to the motor. Complicated devices

Starter Component

1. Contactor

As a electromagnetic switches. Two types 240V and 415V. Will operate when voltage supply to the contactor coil . All auxiliary will operate from NO to NC and NC to NO when the coil energized. No-volt coil or No-volt release concept All the auxiliary contactor will release will spring action when magnetic force are discharge.

Contactor Concept
Magnetic Force Constant Contact

Auxiliary contact

Magnetic Force

Contactor Figure
Contact Frame Constant Contact Spring Contact ontactAuxiliary C Pushing Spring Cross Bar

Core Pin
Laminated iron Core Operating Coil Laminated iron Core Plate

Supply

Base

CONTACTOR COMPONENT
MAIN CONTACT - To control Main CircuitMengawal litar utama. - Conductor Size are depend on the rating current. AUXILIARY CONTACT Low current- contact 5A. Small contact Only control for control circuit.

OPERATION COIL To produce electromagnet at iron core. Will energize when electricity are supply to iron core.

VARIABLE IRON CORE To move cross bar after coil energized assist by spring. CONSTANT IRON CORE

Laminated. Will energized when electricity are supply. PUSHING SPRING Push the core to the condition before after supply off.

OPERATION CONCEPT
-

Functions with 240V and 415V incoming supply. Coil will energized when electricity are supply to the coil and electromagnetic occurred. Constant contact are push to top and move the crossing bar/plate. Crossing bar will move the main contact from open to close and close to open. Contact size are depend on the carried rating current.

MAINTENANCE - Always clean the contactor contact inside.. - Make sure spring tensionalin good condition - Tighting screw could be in good condition.
ADVANTAGES DISADVANTAGES

1.Able to control from other place and remote 1.Expensive for domestic control. installation. 2.Able to to off the circuit when breakdown. 3.As a protection device when overload and short circuit occurred. 4.Able to control High current of the motor .

CONTACTOR SYMBOL
Normally Open Normally closed

THERMAL OVERLOAD RELAY

 Its

a protection devices to avoid any damage at the motor . There are usually broken at the motor. : - Short circuit. - wrong connection Thermal Overload is protection devices to protect overload at the motor. Series connection to the motor. Current are flowing through Thermal Overload Relay to the motor.

FIGURE OF THERMAL OVERLOAD RELAY ( NORMAL CONDITION )

FIGURE OF THERMAL OVERLOAD RELAY ( OVERLOAD CONDITION )

THR SYMBOL
Normally Open Normally closed

COMBINATION SYMBOL

Operation Concept (Overload relay)

Every THR are completed with potential current rating. Chosing Range should be suitable with full load current of the motor. THR setting value is 125% of full load current of the motor.

THR Example calculation

Question A three phase motor are connected to 415V, rating horse power is 3.3 hp and 50 hz with 0.8 power factor. Determine setting value of current to protect the motor.

Answer

P = 3 x VI cos ( Pin formula ) IL = P 3 x VL cos IL = 3 x 746 3 x 415 x 0.8 = 3.89 Amp I setting = 1.25 x 3.89

So setting value is = 4.86 Amp

DIRECT ON LINE STARTER

Call as a D.O.L starter. This starter are commanly use for small rating power of the motor.( 0.373kw t0 3.73kW or in hp h.p hingga 3 h.p ) Component part in this starter circuit can be change but should be in series connection each component. Starting current motor are used for this starter is 6 to 8 time of running current or full load current. If the full load current for one motor is 8A.So starting current of the motor is between 48A to 64A.

Usually this starter are used for the air-condition,Vaqum and etc. The limit of load is 3.0 hp.More then 3.0 hp are not suitable. Total load are cannot exceed 6 to 8 of running current because it will disturb supply source to others load. But at power plant it this starter are used for the biggest motor horse power such as 100k and above. That is because power plant are generated the source and not disturb supply source to others load

Advantages and Disadvantages of D.O.L Starter

Advantages
1.

Disadvantages
1.

2.

High starting torque and shortly time to maximum speed. Simple characteristic and for maintenance and also cheapest price.

2.
3.

High starting current.Will disturb other system. Need more protection devices for safety. Not sensitive /action.

D.O.L STARTER Control Circuit

Figure 1

Supply Start Button

Coil

Neutral

C
Stop Button NO auxiliary contact Thermal Overload Relay

Figure 2

Supply Start Button Thermal Overload Relay Neutral Coil

C
Stop Button

NO auxiliary contact

Figure 3

Supply Thermal Overload Relay Neutral Start Button

C
Stop Button Coil NO auxiliary contact

Figure 4

supply

Start Button
S5

Neutral
S6

Stop Button

C
S1 S2 S3 S4

THR Coil

S7

NO auxiliary contact

D.O.L Starter Main Circuit

Three Phase Supply
R Y B

Contactor Coil

THR

3 Phase Motor

STAR DELTA STARTER

Consist 4 types of Star Delta starter with additional i. Star Delta Starter without resistance ii. Star Delta Starter without resistance ( Forward Reverse Operation ) iii. Star Delta starter with resistance iv. Star Delta starter with resistance (Forward Reverse Operation ) Additional accessories include limit switch,floot switch,relay and etc.

Motor will operated in start connection at a few second.After that motor will operated in delta connection.

START----------------------------STAR OPERATION TIME----- DELTA

Current in start connection is 58% or 1/ 3 from starting current.

Current In Star = 58% x ( 6 to 8 x Running current )

Follow IEE regulation this starter are suitable for 10hp of the motor.

Commanly use for : i. Motor Valve ii. Electrical Pump iii. Converyor belt iv. Air-Condition System For Star Delta with resistance,the resistance/rotor are connected to Delta connection part. Its function is to reduce current value when it change to the delta connection/operation. Advantages of this starter is , It can reduce jerking to the motor when it change to delta operation

Advantages and Disadvantages of Star Delta Starter : Advantages Disadvantages

i. Limit for use.Only 3 hp to 10hp. ii. Difficult to wiring. iii.Easy to burn the motor if wrong connection.

i. Can On and off every time. ii.Simple Maintenance/rarely maintenance compared to auto-trans starter iii.Low cost for commisioning

STAR DELTA CONTROL CIRCUIT

N

MCB 6A

ON

O/L
L

OFF

TDR DC
SP LC

THR

LC
SP

TDR

DC DC
G

SP
DC
TDR LC R

STAR DELTA MAIN CIRCUIT

L1 L2 L3

( 3 Phase Supply ) (main switch)

(main fius )

Star point

O/L

O/L

O/L

A1

B1

C1

B2

C2

A2

C1 B1 A1

C2 B2 A2

3 Phase Induction Motor

AUTO TRANSFORMER STARTER

Its Special starter in market. Its can reduce and limit the voltage at the motor when starting. The voltage connection to the coil can be limit to anything percent when there are connected in star connection. During starting ,auto-transformer are in low limit at main winding that are connected to the source and secondary winding are connected to the statorbcoil. So,its can assist to reduce voltage during starting and current are stay at 70% of autotransformer step.

That is only 70% of full load voltage to the motor when the current are reducing to suitable value current rating. In this situation we must allert to autotransformer because it must in star connection and no in open circuit connection. If open circuit, high voltage are done at autotransformer and its very dangerous. Then,motor are operated without autotransformer by using automatic controller. Normally,this starter are use for motor 3hp to 10 hp

The types of Auto-tranformer are commonly is single phase or three phase. By using this starter ,auto-transformer can step up or down the voltage depend on the load of motor. This starter are used for any starting torque regulating regulating for the three phase motor are moving different potential load. The starting torque regulation can be reduce the voltage to the motor. By using the step level ,this starter are suitable to move the load .

So ,with this way the current are reduce during starting and its safety with rating of the load. When the rotation of the motor are 70% until full load,auto-transformer will disconnected automatically so the motor operated with full voltage supply. Normally ,the rating step of auto-transformer is 40 %, 60 % and 75 % of line voltage.

Advantage and Disadvantages of AutoTrans Starter

Advantages i. ii. ii. Flexible rating step inside. Suitable for different load of motor. Less power losses at accessories device. i.

Disadvantages Sometimes,voltage disturbing occurred because no neutral line in circuit. High voltage occurred when open circuit in star connection at

ii.

Continue
Advantages i. Disadvantages

Suitable for both connection i. High Cost spend for Autoof the motor.,delta or star transformer. connection. ii. Thre are not maximum torque ii. Only 3 or 4 Terminal during starting. connection of the motor, So,Not suitable for motor are not 6 or 7 connection wire need high starting torque during such as star delta starter. starting. iii. Limit for medium level of motor

AUTO-TRANSFORMER CONTROL CIRCUIT

Fuse

O/L

OFF S ON S T M

R2 M R1

S N

L1

L2

AUTO-TRANSFORMER MAIN CIRCUIT

L1 L2 L3

FUSE/ MCB

Thermal Overload Relay

U1

V1

W1 AUTO TRANSFORMER

U2 V2 U V W W2 U3 V3

W3

3 Phase Motor

AUTO-TRANSFORMER MAIN CIRCUIT

R Y B

3 phase supply

MCB

MCB

MCB

3 phase mcb / MCCB

LC TC

AUTO-TRANS

SP

THR

MOTOR

3 phase induction motor

Penghidup Motor Rintangan Rotor

Penghidup ini juga dipanggil penghidup motor rotor berperintang. Ia hanya digunakan untuk motor jenis rotor berlilit (Slip ring). Pada asasnya bahagian stator disambung terus kepada penghidup talian terus sementara bahagian rotornya disambung melalui gelang gelincir ke alat rintangan. Apabila motor dihidup rintangan rotor berada pada nilai maksima. rintangan ini akan akan mengurangkan arus mula di rotor secara beransur ansur

Penurunan nilainya adalah selaras dengan pertambahan kelajuan sahingga apabila motor mencapai kelajuan maksima dan ketiga tiga lilitan dilitar pintaskan. Ia biasanya digunakan di rumah pam, pemampat udara, sistem hawa dingin (kerja berat) dan sebagainya. Iaitu motor-motor yang terdiri lebih daripada 25 k.k . Mengikut peraturan Elektrik ( Bekalan Lembaga ) 1949, Penghidup secara rotor berperintang boleh digunakan untuk motor-motor melebihi 25 k.k.

Bagi penghidup secara rotor berperintang,ia perlu menggunakan perintang yang sesuai dan dilengkapi dengan pelepas tiada- voltan. Fungsi perintang di rotor ialah untuk mengurangkan arus mula di rotor. Ia juga boleh digunakan untuk mengawal kelajuan motor.

Kebaikan penghidup rintangan motor

i.

Sesuai untuk kerja yang memerlukan daya kilas yang tinggi semasa menghidup. ii. Gelung stator memperolehi voltan bekalan dengan sepenuhnya. iii. Sesuai untuk motor-motor yang disambungkan secara bintang atau delta distator.

Keburukan penghidup rintangan motor

i. Ianya terhad kepada motor jenis rotor berlilitan ii. Memerlukan penyelengaraan tambahan. iii. Banyak kehilangan kuasa di motor.

Gambarajah Litar Kawalan Penghidup Motor Rotor Berperintang.

O/L NC MCB 6A NO PB OFF PB ON C1 C1 C1

C2 TDR 1

TDR1 C2

C3 TDR 2

TDR2 C3

C2 RUNNING LIGHT

LAMPU PENUNJUK BEBAN LAMPAU

Gambarajah Litar Utama Penghidup Motor Rotor Berperintang.

Bekalan 3 fasa
MCB

C1

O/L

S1 F3 PERINTANG PERINGKAT 2 F1 PERINTANG PERINGKAT 1

S2 E3

S3 D3

C2

C3 E1 D1

Penghidup Motor 3 fasa kawalan Hadapan dan belakang

Sepertimana kita tahu bahawa motor aruhan 3 fasa boleh diputarkan samada dalam putaran ikut jam atau lawan jam. Untuk menyongsangkan arah putaran motor adalah dengan cara menukarkan turutan fasa bekalan masukan seperti:

RYB = RBY

Untuk meyongsang arah putarannya kita memerlukan penghidup dengan kawalan suis kendalian tangan atau secara automatik. Ini adalah kerana motor 3 fasa yang mempunyai kadaran kuasa k.k atau lebih memerlukan penghidup untuk menggerakkan nya.

Berikut adalah diantara jenis-jenis penghidup dengan kawalan kehadapan dan kebelakan / mara songsang :

i. ii. iii. iv.

Penghidup Talian Terus mara songsang. Penghidup Bintang Delta mara songsang. Penghidup Alatubah-Auto mara songsang. Penghidup rotor berperintang mara songsang.

Penghidup Talian Terus mara-songsang. Litar Kawalan dan litar utama Penghidup
Bekalan 3 fasa
R Y PB3 B

Suis Utama

F O/L Fius/ MCB

R

Contactor yang digunakan adalah jenis 415 Volt

F

Fius

PB1 F R F

PB2

Note: PB1 : Mara

O/L

PB2 : Songsang

Penghidup Bintang-Delta Mara songsang Litar kawalan.

LAMPU TRIP N

PB1

R F F T D S

L
MCB O/L STOP F

Contactor yang digunakan adalah jenis 240 Volt

R

PB2

S T R T S D

F R

Note: PB1 : Mara. PB2 : Songsang

Litar Utama
R Y B Ke litar kawalan

3 phase MCB / MCCB

A1

B1

C1 S

Beban lampau

A1

B1

C1

B2

MOTOR
A2 B2 C2

C2 A2