ELECTRICAL AND

INSTRUMENTATION
MAINTENANCE TEAM
Training on Motor starters
BY:FITSUM GIRMA
MOTOR STARTER
MOTOR STARTER
Momentary and maintained PB
Interlock b/n two motors
Sequence interlock
Individual start stop
Auto/off/hand control with Emergency
stop/stop/start/hold on
Auto/off/Hand
MOTOR STARTER
Full voltage motor starter/Across the line
starter(DOL).
Reduced voltage starter(stator resistance , star
delta ,auto transformer ,soft starter ,VFD , Rotor
resistance starter).
 NEED OF STARTER/REDUCED
 If a rated stator voltage is applied to the motor at the time of starting, then the
motor will draw heavy starting current.
 This will lead to excess i2R losses in the winding which will overheat the
motor.
 Secondly due to a heavy current drawn from the AC supply voltage will
reduce.
 The heavy starting current may damage the motor windings.
 In order to avoid these problems, we can use some kind of a starter to start the
induction motor safely.
 Comparison of starter based on inrush current
STARTER TYPE STARTING CURRENT ( %FLA)
VFD 100%
STAR DELTA STARTER 200-275%
SOLID STATE SOFT STARTER 200%
AUTO TRANSFORMER STARTER 400-500%
DOL STARTER 600-800%

Starting current comparison for 100 KW ,205A motor

Starter type Starting current(% FLC)
VFD 205A
STAR DELTA STARTER 410-564A

SOLID STATE STARTER 410A

AUTO TRANSFORMER 820-1025A
DOL 1230-1640A
……continued
 An induction motor will develop far too much torque when connected
directly to the supply.
 At the instant of start-up, there are some un-necessary effect on
electrical and the mechanical components.
UN-NECESSARY MECHANICAL EFFECTS
The sudden impact at start up on the load, followed by the rapid
acceleration to full speed causes excessive wear on :-
 Belts and pulleys
 Gears and chains
 Couplings and bearings
 Cavitation in pumps etc.
UN-NECESSARY MECHANICAL EFFECTS
UN-NECESSARY ELECTRICAL EFFECTS
 A heavy current surge on the electrical supply which can be severe
enough to cause voltage dips and flickering lights.
 Burning of contacts due to high currents which are many times the
motor full-load current.
Voltage dip/sag/
Light flickering/diming
Burned contactor contacts example
 PROBLEMS ARISES BY THIS EFFECTS
 Continuous maintenance.
 Greater chance of unscheduled shutdowns.
 Oversized mechanical and electrical components to cater for the power
surge on start up.
 Short component life.
 SOLUTION OF THE PROBLEMS

STARTER
By Adjusting voltage during starting, the current drawn by the motor and the
torque produced by the motor can be reduced and controlled.
 FUNCTIONS OF STARTERS
 Start and stop the motor.
 Limit inrush current where necessary.
 Permit automatic control when required.
 Protect motor and other connected equipments from over load, over voltage,
no voltage, under voltage, single phasing etc.
COMPONENTS OF MOTOR STARTERS
CONTACTOR
DEFINATION
 A contactor is an electrically controlled switch used for switching an
electrical power circuit , similar to a relay except with higher current
ratings.
 It is an electro-mechanical switching.
CONTACTOR
FEATURES
 A contactor is a relay that is used for switching power.
 Relay : electrically operated switch
 They usually handle very heavy loads like an electric motor, lighting and
heating equipment and so on.
 Though their output is used for switching very high loads, they are controlled
by a circuit with very less power.
 According to the loads they handle, they vary in sizes from a small device to as
huge as a yard .
CONTACTOR
• Though they are used for switching purposes, they do not interrupt a
short-circuit current like a circuit breaker
• They have ratings ranging from a breaking current of a few amperes and
24 DC volts to thousands of amperes with many kilo volts.
Contactor/construction
Components of contactor
 Movable contacts
 Stationary contacts
 Armature
 Spring
 Electromagnet
 Power circuit
 Control circuit
 coil
Moving and fixed contacts of a contactor
OPERATING PRINCIPLE
Replacement of contactor
Check current rating of contactor/KW
Check voltage rating of operating coil
Check Utilization Category
Check aux. contact requirement
Choose suitable Overload relay
contactor
 Types of coils use in contactor

1. AC coil
2. DC coil

 In AC coil
1. 110 volt
2. 220 volt
3. 380 volt

 In DC coil
1. 12 volt
2. 24 volt
Control circuit with 24v ac contactor coil
UTILIZATION CATEGORIES

UTILIZATION CATAGORIES: contactors are catagorized based on type of load and operating
conditions/duty cycle/
 AC1-Resistive Load ( PF 0.95 or above)-constant current loads/constant resistance---Heaters
(constant current during starting , running and stopping)
 AC2-Inductive load---this category is used for starting slip ring motors
 on closing , the contactors make starting current which is about 2.5 times the rated current of the
motor.
 AC3-Inductive load-squirrel cage induction motors
 On closing, the contactor makes the starting current, which is about 6 to 8 times the rated current of the
motor
MY contactor does not close…what to do?
 Check the supply voltage is available or not. If not find the origin of the
failure.
 Check the coil voltage . the coil voltage and the supply voltage must be
similar.
 If the coil is DC….respect polarity rule . positive cable on A1 and
negative cable on A2.
 Check if the coil is failed or not. check continuity/coil resistance…coil
resistance close to 0.1ohm/short circuit…coil resistance infinite/open ckt
OVERLOAD RELAY
• THERMAL OVERLOAD RELAY
THERMAL OVERLOAD RELAY
• Working principle
THERMAL OVERLOAD RELAY
BIMETALIC THERMAL OVERLOAD RELAY
ELECTRONICS OVERLOAD RELAY
ELECTRONICS OVERLOAD RELAY
What you need to do when overloads in the motor starter trip?
 Check the motor shaft freely rotates or not
 Determine if the overload setting is properly adjusted. Overload relay
setting depends on FLA ( Full Load Ampere ) of motor. Normally setting
for overload is 105-110% of motor FLC.
 An electrical possibility is that the motor has an open phase/single phasing.
Check the motor starter contactor, the fuses, and the overload relay.
 Rectify the root cause of overload and reset the overloads by push the reset
button. Start the motor and check the running motor amps and compare
to rated FLA and overload heater size using a clamp-on ammeter.
….continued

 If the amps are greater than needed to trip the motor the reason is
generally mechanical overloading. This could be bearing failure, too
much load, motor/load misalignment, etc.
 If the amps are less that FLA and the Overloads are properly sized/set
properly the motor overloads should not trip. In this case the Overload
block is likely to be defective.
Power circuit for reversible star delta/4 contactor
Reversible star delta control circuit/4 conctors
Reversible star delta control circuit/5 contactor
Limit Switches
….continued
LIMIT SWITCH
 Limit switch is mechanically operated device, the prime function of this
switch is to stop or reverse a motor.
 Limit switches provide over travel protection.
 Mostly this switch is used in a machine tools , cranes, panal doors,
refrigerators light, conveyors…,etc.
• Limit switches are constructed of two main parts: the body and the operator
head (also called the actuator)
• The body consists of NO,NC contacts and Spring(momentary)
….continued
LIMIT SWITCH
Lateral movement of overhead crane by a motor
application example
Limit switch application example…machine tools
Continued….
The operation of the circuit can be summarized as follows:
Pressing the momentary forward push button completes the circuit for the F coil,
closing the normally open maintaining contact and sealing in the circuit for the
forward starter coil.
At the same instant, the normally closed interlock contact F opens to prevent the
reverse direction of the motor.
To reverse the motor direction the operator must first press the stop button to DE
energize the F coil and then press the reverse push button.
If over travel position should be reached in either the forward or reverse direction, the
respective N.C. limit switch will open to prevent any further travel in that direction.
The forward direction is also interlocked with a normally closed R contact.
Limit Switch Application example Hoisting/crane
PRESSURE SWITCHES
…..continued
PRESSURE SWITCH
 Pressure switches are used to monitor and control the pressure of
liquids and gases.
 They are commonly used to monitor a system and, in the event that
pressure reaches a dangerous level, open relief valves or shut the
system down.
 Application example(compressed air receiving tank , turbine gear
box, weko gear box…..)
Working principle
PRESSURE SWITCH
……continued
Application example…compressor Receiving Tank
….continued
 The compressor circuit shown above consists of a compressor drive
motor, a compressor unit, and a tank. The operation of the circuit
can be summarized as follows:
 The pressure switch is used to stop the motor when tank pressure
reaches a preset limit.
 When the preset system pressure is reached, the N.C. contacts of
the pressure switch open to DE energize the motor starter coil and
automatically switch the compressor motor off.
PRESSURE SWITCH example
Star delta starter with pressure switch
FLOAT SWITCH
…continued
Float switch
 A float switch is used to sense the height of a liquid.
 Level sensor/used to detect the level of liquid with in a tank
 Float switches provide automatic control for motors that pump liquid
from a reservoir or into a tank.
 The switch may be used to control a pump, as an indicator, an alarm, or
to control other devices.
Continued….
Continued….
FLOAT SWITCH/ tank filling pump/the motor stops when the tanks is
full
Float switches
The operation of the circuit can be summarized as follows:
 The float switch contacts are open when the float forces the operating
lever to the up position.
 As the liquid level falls, the float and rod move downward.
 When the float reaches a preset low level, the float switch contacts close,
activating the circuit and starting the pump motor to refill the tank.
Float switch application/tank emptying pump/the
motor starts when the tank is full
Floater switch application example
 Let’s start by looking at Control Schematic above with two Normally
Closed switches. This circuit can be used to control a pump that fills a
tank. The first switch (L) is set at the minimum liquid level desired in the
tank. The second switch (H) goes at the maximum desired level.
 When the liquid is below both switches, they are both closed; the pump
runs, filling the tank. As the liquid fills past the first switch, it opens.
However, seal-in relay A has been activated and closed, bypassing the now-
open switch L (effectively “sealing it in”), so the pump continues to run
until the high-level switch H opens. When the high-level switch opens, the
motor relay P opens, stopping the motor, and seal-in relay A opens.
 So no more liquid is coming into the tank from this pump. Let’s say a valve
downstream of the tank is opened, allowing liquid to drain out of the tank.
As the liquid level falls, high-level switch H closes. But since both low-level
switch L and seal-in relay A are open, the pump motor does not start.
 In fact, the liquid level in the tank must fall below low-level switch L before
the motor will start. At that point, both the low-level and high-level switches
will be closed, completing the circuit, and activating motor relay P to start
the pump. At the same time, seal-in relay A will be activated, closing the by-
pass around low-level switch L. So when low-level switch L opens as the
pump fills the tank, the seal-in relay keeps the circuit closed, and the pump
keeps pumping
 Once the liquid level falls below the low-level switch, the pump will run
until both switches are open. The liquid level can fluctuate up and down,
the low-level switch can open and close, and the pump will continue to
run smoothly. Similarly, once the high-level switch opens, the pump will
not run until both switches have closed. Regardless of level fluctuations,
no more pump motor flutter.
Alternate operation of two pumps with floater switch
Alternate operation of two pumps with floater switch
 If the frequency of operation of pumping liquid into a tank is to frequent,
too much stress is subjected to a single motor pump. In such case the life
span of the motor may not last long. To avoid to much stress to a single
motor pump, it is wise to add another motor pump. The two motor are
design to operate alternately. Figure A illustrate two motor pumps that
alternately pumps liquid into tank.
Alternate operation of two pumps control circuit
with floater switch
 Figure (B) illustrate the schematic diagram of the control circuit of the
“Alternate Operation of a Two Motor Pump”. Closing the toggle switch SW
will place the control circuit ready for operation.
 As the liquid level in the tank drops to the lower limit LL as shown in
figure (A). The float switch* contact FS (1-2) will close, see figure (B).
Contactor M1 (A-B) is energize by the current that flows from the line L1,
toggle switch SW, float switch FS (1-2), contact M2 (11-12), contact R (11-
12), contactor M1 (A-B) and to line L2. contact M1 (13-14) will close to
maintain contactor M1 (A-B) continuously energized. Contact M1 (11-12)
will open to prevent contactor M2 (A-B) from being energized. Contact M1
(1-2) will close to energize relay R (A-B).
 With relay R (A-B) energize, contact R (1-2) will close to maintain relay R
(A-B)  continuously energized. Contact R (13-14) will close and contact R
(11-12) will open. At this condition, the motor pump M11, controlled by
contactor M1 (A-B), will pump liquid into the tank. The float switch FS (1-
2) remains close as the liquid in the tank rises up.
 When the liquid reaches the upper limit UL, the float switch contact FS (1-
2) will open. This de-energize contactor M1 (A-B) to stop the motor pump
M11 from pumping liquid into the tank. Also contacts M1 (13-14) and M1
(1-2) will open. Contact M1 (11-12) will open. As liquid is drain from the
tank and its level drops, the float switch FS (1-2) remains open. Relay R (A-
B) is still energized.
 When the level of the liquid reaches the lower limit LL, the float switch FS (1-2)
will close again. Contactor M2 (A-B) is energized by the current that flows from
line L1, toggle switch SW, float switch FS (1-2), contact M1 (11-12), contact R
(13-14) which is now closed, contactor M2 (A-B) and to line L2. contact M2 (11-
12) will open to prevent contactor M1 (A-B) from being energized. Contact M2
(13-14) will close to maintain contactor M2 (A-B) continuously energized.
Contact M2 (21-22) will open to de-energized relay R (A-B)
 With relay R (A-B) de-energized, contact R (11-12) will close, and contacts R
(13-14) and (1-2) will open. At this condition the motor pump M22 controlled by
contactor M2 (A-B) will pump liquid into the tank. The float switch FS (1-2)
remains close as the liquid in the tank rises up
 When the liquid level reach again the upper limit UL, the float switch
contact FS (1-2) opens. This de-energize contactor M2 (A-B) and stops
the motor pump M22 from pumping liquid into the tank. Contacts M2
(11-12) and M2 (21-22) will close and contact M2 (13-14) will open. The
condition of the circuit is brought back to the shown in figure (B).
Alternate operation of the motor pump M11 and M22 is repeated as the
liquid alternately rises up and drop down.
Temperature switches
Temperature switches
 Temperature control devices monitor the temperature or changes in
temperature for a particular process.
 Temperature switches open or close when a designated temperature is
reached.
 Temperature switches comprise sensing elements and switching contacts
housed in a single mechanical assembly.
 Temperature control devices are used in heating or cooling applications
where temperature must be maintained within preset limits.
Liquid Filled Temperature Switch
Liquid Filled Temperature Switch
Liquid Filled Temperature Switch
• The capillary tube temperature switch, illustrated in Figure above,
operates on the principle that a temperature-sensitive liquid will expand
and contract with a change in temperature.
• Pressure in the system changes in proportion to temperature and is
transmitted to the bellows through a bulb and capillary tube.
• As the temperature rises, the pressure in the tube increases.
• Similarly, as the temperature decreases, the pressure in the tube
deceases.
BIMETALLIC STRIP TYPE TEMPRETURE SWITCHES
 A bimetallic strip comprised of two metals having different thermal co-
efficient of expansion firmly joined together either by rolling or welding.
 When heated, the strip is bends on account of differential expansions of
two metals.
BIMETALLIC STRIP
BIMETALLIC STRIP TYPE TEMPRETURE SWITCHES
Fan motor control using thermostat
PHASE FAILURE PROTECTION RELAY
…..continued
RELAYS
PHASE FAILURE RELAY
Single phase means an open circuit in one of the phase of 3phase
supply to an induction motor which under running condition.
To maintain the same power input to the motor during single phasing
the current in the remaining two phases will increases by 1.73 times.
To avoid failure of the motor due to single phasing phase failure relay
are used
Phase failure relay application example
TIMING RELAYS/TIMERS
Pneumatic timer/Dashpot
Pneumatic timers
 Pneumatic timers manage their timing function by controlling fluid flow or
airflow through a small orifice.
 The bellows design allows air to enter through an orifice at a
predetermined rate to provide time-delay increments.
 As soon as the coil is energized or DE energized, the timing process begins and
the rate of airflow determines the length of the time delay.
 Smaller orifice openings restrict the flow rate, resulting in longer time delays.
 Pneumatic timers have relatively small adjustable range settings(0.05 to 180
seconds).
Motor Driven timers
Motor Driven timers
• The motor turns the mechanism and actuates normally open or normally
closed contacts.
• Adjustable on/off tabs set along the clock’s timing wheel trip the contact
open or closed.
Solid state/Electronics Timer
 Solid-state timing relays use electronic circuitry to provide their timing
functions.
 solid-state timing functions are initiated when the electronic circuit of the
timer is energized or a triggering signal is received or removed.
• The operation of the device can be summarized as follows:
• Connections provided include timed contacts (C1,C2), voltage input (L1,
L2), and external trigger switch (S1, S2).
• A timing-delay period of from 0.1 to 2 seconds is set by the adjustment of an
internal potentiometer located on the front panel of the timer.
• The timer is energized continuously, and timing is initiated when the external
trigger circuit is closed.
TIMING FUNCTIONS
ON DELAY TYPE
• Once energized, on delay timed contacts change state after a set time
period has passed.
• After that time has passed, all normally open timed contacts close
and all normally closed contacts open.
• Once the timed contacts change state, they will remain in this
position until the power is removed from the coil or electronic circuit.
• Application: Star Delta starter
ON DELAY CIRCUIT
TIMING FUNCTIONS
OFF DELAY TYPE
• Once DE energized, on delay timed contacts change state after a set time period has
passed.
• After that time has passed, all normally open timed contacts close and all normally
closed contacts open.
• Once the timed contacts change state, they will remain in this position until power
is GIVEN TO the coil or electronic circuit.
Off delay CIRCUIT
Recycle Timer
RECYCLE TIMER

• The contacts of a recycle timer alternate between the on and off states when the timer is
energized.
• Upon application of input voltage, the first delay period (TD1) begins and the output
remains deenergized,or off.
• At the end of the first delay, or off period, the relay coil will energize and the second delay
(TD2), or on period, begins.
• When the second delay period ends, the relay deenergizes
• This recycling sequence will continue until input voltage is removed.
• Recycle timers have back up battery.
• Application: Street light, Deep Well pumps
Push buttons
 Pushbutton switches are commonly used in motor control applications to
start and stop motors.
 A push button operates by pressing a button that opens or closes contacts
 Abbreviations N.O. (normally open) and N.C. (normally closed) represent
the state of the switch contacts when the switch is not activated.
 The N.O. push button makes a circuit when it is pressed and returns to its
open position when the button is released.
 The N.C push button opens the circuit when it is pressed and returns to the
closed position when the button is released.
Push Buttons
Push Buttons
The operation of the circuit can be summarized as follows:
 Pressing the start push button completes a circuit for the M coil, causing
the motor to start, and the M contact holds in the M coil circuit.
 Pressing the stop button, disconnects the path. M coil DE energize and M
contact will open.
 Start push button ( are green and momentary)
 Stop push buttons (are red and momentary)
 Emergency stop button(are red and maintained)
Push Buttons
• Momentary buttons : Momentary type pushbutton operators return to
their normal on or off state as soon as the operator is released.
• Maintained buttons : Unlike momentary pushbutton operators,
maintained types require you to press and release the operator to switch
the contacts to their on state and to press and release the operator a
second time to return the contacts to their off state.
Momentary and maintained PB example
EMERGENCY STOP
The three most common types of Emergency stops
• Push pull: the operator is pushed in and locks into stop; released by pulling
back. Indicated by the circle symbol on the head.
• Twist release : the operator is pushed in and locks into stop, released by
twisting . Indicated by the circular arrows on the head.
• Key release : the operator is pushed in and locks into position to stop;
released only with a key.
Continued….

Push pull Key release

Twist release
Continued…
• Contact : The conducting part of a switch that makes or breaks a circuit.
Available as “normally open” (NO), in which the circuit is open in its neutral
state, or “normally closed” (NC), in which the circuit will be closed. Activation of
the operator will reverse the neutral state of the contact.
• Operator/Actuator: The part of the device that is touched to operate, i.e., the
pushbutton head.
• Contact block/switch unit : The part of a pilot device that encapsulates the
contact. Blocks are held to the back of a device with a contact block holder.
• Legend plates: are the labels that are installed around a push button and identify
its purpose.
• Legend plates
Switch unit/contact block
continued
Selector switches
…..continued
• The difference between a push button and selector switch is the operator
mechanism.
• A selector switch operator is rotated (instead of pushed) to open and close
contacts of the attached contact block.
• Switch positions are established by turning the operator knob right or left.
• Selector switches can be maintained or momentary ( spring return ).
• Selector switches are available in two-, three-, and four-position
types
TWO POSITION SELECTOR SWITCH
continued
• In the above example PL1 is energized when the switch positon is position 1.
• PL2 energize when the switch position is position 2.
• Contact truth table: a table indicating the contact position of a selector
switch in a circuit.
Position
contacts
A B
1 X
2 X
Three position selector switch
Three position selector switch
• In the above example coil 1 is energized when the switch position is
manual.
• Coil 2 energized when the switch position is AUTO.
• None of the coils will energize at off position.
Control CKT with Auto/manual SW example
Pilot lights
…..continued
Pilot lights
 Pilot lights provide visual information about the circuit's operating
condition.
 Pilot lights are normally used for “ON/OFF” indication, caution, changing
conditions, and alarm signaling.
 Pilot lights come with a color lens, such as red, green, amber, blue, white, or
clear.

 A green pilot light located on a control panel would give visual

indication that a motor was running
 A red pilot light would give visual indication that a motor was
stopped.

Yellow or amber light indicate motor was tripped ( due to

overload relay , pressure switch, temperature switch ,ground fault…etc)
Continued….
Types of Starter for 3-Ph InductIon motors
 For slip-ring induction motors:
 Rotor rheostat starter

 For squirrel cage induction motors:

 D.O.L starter
 Primary resistance starter
 Auto transformer starter
 Star delta starter

 Other starters:
 Soft starters
Rotor Resistance Starter
• This starter is used with Wound Rotor/SLIP RING induction motor.
Four stage slip ring motor starter power circuit
Four stage slip ring motor starter control circuit
Six stage slip ring motor starter power circuit
Six stage slip ring motor starter control circuit
Rotor Resistance Starter
Rotor Resistance Starter
 In rotor resistance starter the three terminals of the rotor winding are
connected to an external resistances through slip rings.
 Full supply voltage is applied across the stator. Resistances are fully in the
circuit at starting , so that the starting current is reduced. The external
resistance connected in each phase of the rotor circuit not only reduce the
current at starting but increases the starting torque also due to improvement
in power factor.
 The rotor circuit resistance is gradually cut out , as the motor speeds up and
during normal running condition ,the rotor circuit resistance is completely cut
out and the slip rings are short circuited.
D.O.L.(Direct On Line) starter
D.O.L.(Direct On Line) starter
 A Starter Which Connects A Motor Directly Across The Line Is Called D.O.L. Starter.
 In This Method, The Motor Is Connected By Means Of A Starter Across The Full Supply
Voltage.
 It Is Very Simple, Inexpensive, Easy To Install And Maintain.
 It Consists – START Button
OFF Button
Electromagnetic Contactor
Overload Relay
 Switching By This Starter Is Directly From Line Without Any Provision To Control The Starting
Current i.e. There Is No Device To Reduce The Starting Current In This Starter.
D.O.L.(Direct On Line) starter
D.O.L.(Direct On Line) starter
 L1,L2,L3 – SUPPLY LINES
 Circuit Breaker/Fuse—short circuit/earth fault protection units
 KM – MAIN CONTACTOR
 KM1-main contactor auxiliary contact
 O/L-thermal overload relay
OPERATION OF D.O.L STARTER

1) When START Button Is Pressed

 When Start(s1) Button is pressed, Path is

L1 - S2 - S1 – C – OL - L2
 Coil C Is Energized ,It Closes Contacts M A and Connects The Motor Across The Line.
 Maintaining Contact MA Is Used To Keep The Holding Or Operating Coil Energized
After The Finger Is Removed From START Push Button (S1).
OPERATION OF D.O.L STARTER

2).When OFF Button Is Pressed

 When OFF(s2) Button is pressed, Path is Disconnected
 Coil C Is De-Energized, The Main Contacts MA are Opened. Supply To Motor
Is Disconnected And Motor Stops.
D.O.L STARTER
 Basically There Are Two Types Of Protection In This Type of Starter

1)Under Voltage Protection

2)Overload Protection
Under Voltage Protection
• When Supply Voltage Is Not Sufficient Or There Is Failure Of Power
Supply , The Coil C Is De-Energized And Motor Will Be Disconnected.
D.O.L STARTER
Overload Protection
 The Motor Is Protected Against Overload By A Thermal Overload Relay
Which Open Circuits the Control Circuit When Overload occur.
 The Normally Closed Contacts O.L Is Opened And The Contactor Coil C
is De-Energized To Disconnect The Motor From The Supply.
 Only Used For Less Than 5 KW Squirrel Cage Induction Motor
D.O.L STARTER
CHARACTERSTIC OF D.O.L STARTER
 Peak starting current: 6 to 8 Full Load Current.
 Peak starting torque: 100%
ADVANTAGES OF DOL STARTER:
 Most Economical and Cheapest Starter
 Simple to establish, operate and maintain
 Simple Control Circuitry
D.O.L STARTER
 Easy to understand and trouble‐shoot
 It provides 100% torque at the time of starting.
 Only one set of cable is required from starter to motor.
 Motor is connected in delta at motor terminals.
D.O.L STARTER
DISADVANTAGES OF DOL STARTER:
 It does not reduce the starting current of the motor.
 High Starting Current: Very High Starting Current (Typically 6 to 8 times
the FLC of the motor).
 Mechanically Harsh: Thermal Stress on the motor, thereby reducing its life.
 Voltage Dip: There is a big voltage dip in the electrical installation
 High starting Torque: Unnecessary high starting torque, even when not
required by the load.
PRIMARY RESISTANCE STARTER
 In this method of starting of 3-Phase induction motor ,primary resistance are
connected in all the three phase of the stator winding, as a result the applied
voltage across the stator winding at the instant of starting is reduced to a
fraction x of the rated voltage of the motor. Therefore the initial high starting
current will also reduce by the same fraction.
PRIMARY RESISTANCE STARTER
PRIMARY RESISTANCE STARTER
TWO CONTACTORS
1. LINE CONTACTOR(A)
 First to energize connecting motor to the line voltage through a resistor
 Resistors connected in each line in series with each phase winding of the stator.
 Due to starter resistance in series, each phase winding will receive a reduced
voltage. Due to reduction in the value of V1,the starting current is limited to a
safe value.
 After preset time contactor opens.
PRIMARY RESISTANCE STARTER
2.Accelerating contactor(B)
 Energizes.
 Starter resistance shorted out.
 Full voltage is applied across the stator winding.
PRIMARY RESISTANCE STARTER—example
power and control circuit
PRIMARY RESISTANCE STARTER
• The motor is started by closing the main contactor. This supplies power
to the motor through series starting resistance. The contactor (across
resistors R1,R2,R3) is open thus the current has to pass through the
resistors resulting in voltage drop. Due to voltage drop in these resistors,
the motor gets reduced voltage. A timer is installed with a preset time
delay. When the delay is over, the contactor is closed closing the parallel
switches
STAR-DELTA STARTER
Color to color connection
STAR-DELTA STARTER
• How it works?
 There are two contactors that are close during run, often referred to as the main
contactor and the delta contactor. These are AC3 rated at 58% of the current rating
of the motor. The third contactor is the star contactor and that only carries star
current while the motor is connected in star. The current in star is one third of the
current in delta, so this contactor can be AC3 rated at one third of the motor rating.
 In operation, the Main Contactor (KM3) and the Star Contactor (KM1) are closed
initially, and then after a period of time, the star contactor is opened, and then the
delta contactor (KM2) is closed. The control of the contactors is by the timer (K1T)
built into the starter. The Star and Delta are electrically interlocked and preferably
mechanically interlocked as well.
STAR-DELTA STARTER
In effect, there are four states:
1. OFF State: All Contactors are open
2. Star State: The Main and the Star contactors are closed and the delta contactor is open. The
motor is connected in star and will produce one third of DOL torque at one third of DOL current.
3. Open State: The Main contactor is closed and the Delta and Star contactors are open. There is
voltage on one end of the motor windings, but the other end is open so no current can flow. The
motor has a spinning rotor and behaves like a generator.
4. Delta State: The Main and the Delta contactors are closed. The Star contactor is open. The motor
is connected to full line voltage and full power and torque are available.
This type of operation is called open transition switching because there is an open state between the
star state and the delta state.
STAR-DELTA STARTER
 This is very commonly used starter, compared to the other types of the
starters.
 Star-delta starter can be used, provided the stator of the 3-phase induction
motor is designed for delta connection during its normal operation.
 At starting, the stator winding is connected in star, therefore the applied
voltage to each phase of winding is 1/√3 of the rated voltage of the motor.
 When the motor has picked-up the speed (say 70 to 80% of its normal speed )
the phases of the stator winding are connected in delta.
STAR-DELTA STARTER
 Now full supply voltage is applied across the stator windings.
 This method is cheap but limited to applications where high starting torque is
not necessary e.g., machine tools, pump , motor-generator sets etc.
 Such starters are employed for starting 3-phase squirrel cage induction
motors of rating between 4 and 20 k W.
ADVANTAGES OF STAR DELTA STARTER
 The operation of the star-delta method is simple and rugged
 It is relatively cheap compared to other reduced voltage methods.
 Good Torque/Current Performance.
 It draws 2 times starting current of the full load ampere of the motor
connected.
DISADVANTAGES OF STAR DELTA STARTER
 Low Starting Torque, only 33% starting torque.
 Break In Supply – Possible Transients.
 Six Terminal Motor Required (Delta Connected).
 It requires 2 set of cables from starter to motor.
 The delta of motor is formed in starter and not on motor terminals.
 Low Starting Torque: reduction of the line voltage by a factor of 1/√3 (57.7%)
to the motor and the current is reduced to 1/3 of the current at full voltage, but
the starting torque is also reduced 1/3 to 1/5 of the DOL starting torque
Y-D STARTER OPERATING PRINCIPLE
Y-D STARTER OPERATING PRINCIPLE
 When the start push button is pressed, contactor k2(star) coil is energized.
 The K2(Star) main power contacts close to connect the motor windings in a wye
(or star) configuration.
 The normally open K2 auxiliary contact closes to energize contactor coil K1.
 Now main (K1) and star (K2) contactors are closed hence the motor is running
in star/reduced voltage applied/.
 After the time delay period has elapsed, the timer(K4) contacts change state to
deenergize contactor coil star(k2) and energize contactor coil Main(k3).
Y-D STARTER OPERATING PRINCIPLE
 Now Main (K1) and Delta (K2) contactors are closed hence the motor is
running in Delta/Full Voltage applied/.

 In most wye-delta starters, contactors STAR and DELTA are electrically

and mechanically interlocked. If both contactors were to be energized at
the same time, the result would be a line-to-line short.
AUTO TRANSFORMER STARTER
AUTO TRANSFORMER STARTER
 An auto-transformer starter makes it possible to start squirrel cage induction motors
with reduced starting current, as the voltage across the motor is reduced during
starting.
 In contrast to the star-delta connection, only three motor leads and terminals are
required. On starting, the motor is connected to the tapping of the auto-transformer.
 A specific advantage of this starter is that reduction in voltage during starting, can
be done to any desired level by selecting proper tapping of the autotransformer.
 This method is often employed for starting of large cage motors (rating exceeding
20 kW).
Auto transformer starter operating principle
Auto transformer starter
STARTING CHARACTERSTICS of Auto
transformer
 Motor terminal voltage less than line voltage (by transformer ratio).
 Motor current exceeds line current (by inverse of transformer ratio).
 Starting torque is reduced by the square of the terminal voltage.
SOFT STARTER
SOFT STARTER
Soft-Starter is an
electronic starter
designed to accelerate, deaccelerate
three-phase induction
motors and to control the
voltage applied on the motor
during start and stop.
Starting Principle of Soft Starter
SOFT STARTER
 By using six SCR’s in a back to back configuration , the soft starter is
able to regulate the voltage applied to the motor during starting from 0
volts up to line voltage.
 Feedback from the motor to the logic circuit used to control the SCR
firing for stabilization of motor acceleration.
 Frequency do not change as in VFD
 Only the voltage and current changes.
Soft starting feature

DOL Soft start

Current/speed curve with soft

starter
Soft starting feature
 Adjustable initial voltage =10 – 50% VRated .
 Adjustable ramp time = 1– 30 seconds (can be extended )
Soft stopping feature
Working:
 During ramp-down the controller will gradually reduce the voltage to the motor thus reducing the
torque and current. As a consequence the motor speed will fade off.

 Adjustable stopping time- 1-30s.

Soft starter power circuit example
Soft starter control circuit example
VARIABLE FREQUENCY DRIV(VFD)
VARIABLE FREQUENCY DRIV(VFD)
• A Variable Frequency Drive (VFD) is a type of motor controller that
drives an electric motor by varying the frequency and voltage supplied to
the electric motor.
• Other names for a VFD are variable speed drive, adjustable speed drive,
adjustable frequency drive, AC drive, micro drive, and inverter.
• It controls AC motor speed and torque by varying motor input frequency and
voltage.
VARIABLE FREQUENCY DRIV(VFD)
VARIABLE FREQUENCY DRIV(VFD)
VARIABLE FREQUENCY DRIV(VFD)
Converter/Rectifier
 All VFD’s need a power section that converts AC power into DC power. This is
called Converter/Rectifier.
DC Bus
 The DC bus is the true link between the converter and inverter sections of the
drive.
 Any ripple must be smoothed out before any transistor switches “on”.

Inverter
 Now the inverter converts the DC back to AC of required frequency.
PLC ladder logic for star delta starter
• Main contractor is used to supply power to the windings. It must be
turned on all the time. Initially the star contactor is closed while delta
contactor is open It makes the motor windings in star configuration.
• When the motor gains speed, the star contactor is opened while delta
contactor is closed turning the motor windings into delta configuration.
Programmable logic controller
Ladder logic for star Delta starter
Rung 1 Main contactor 
 The main contactor depends upon the normally open input start push button (I1),
normally closed stop button (I2) and normally closed overload relay.
 It means that Main contactor will only be energized if start button is pressed,
while stop is not pressed and overload relay is not activated.  A normally open
input named (Q1) is added in parallel to the start button I1.
 By doing so, a push button is created which means that once motor is started, it
will be kept started even if start button is released
Rung 2 Star contactor
 Star contactor depends upon main contactor, normally close contacts of 
timer (T1), and normally close contacts of output delta contactor (Q3).
 So star contactor will only be energized if main contactor is ON, time
output is not activated and delta contactor is not energized.
Timer T1
 Timer T1 measures the time after which the winding connection of star
delta starter is to be changed. It will start counting time after main
contactor is energized.
Rung 3 Delta contactor
• Delta contactor will be energized when main contactor (Q1) is energized,
timer T1 is activated and star contactor (Q3) is de-energized.
PLC logic program for DOL starter having limit
switch ,motor on signal lamp and motor stop signal lamp
Start Button I1 :
 Normally open contact (Make contact) is used because the motor should
only start when the button is pressed.
Stop Button I2 :
 Normally close (break contact) contact is used because the button should
normally be closed or high so that the motor keeps on running. It should
open when the button is pressed. It is opposite to start push button.
Overload relay I3 :
 In normal condition, this relay should allow the motor to rotate so
normally close contact is selected for it. In case of overload it will stop
the motor by opening its contact.
Limit switch I4 :
 The motor should only rotate when the limit switch is closed therefore
normally open contact is used.
Output Q1, Q2, Q3 :
• Relay coil Q1, Q2 and Q3 represent motor output, motor indication ON
and indication OFF respectively.
• ON indicator gets input from normally open input which depends upon
output Q1. OFF indicator is fed by normally close input which depends
upon output Q2.
Input Q1/Self hold ( for continuous rotation)
 Since it is required that once push button is pressed, motor should run continuously even
if the push button is released.
 To achieve this part, an input Q1 (normally open) is used and connected in parallel with
I1. This input depends upon output Q1.
 When output is high, input Q1 is also high. Since input Q1 provides parallel path with I1,
so if any of them is to be high, motor will run (if other conditions are also satisfied).
 Start button (Normally open), stop button (Normally close), overload relay (Normally
close) and limit switch (Normally open) are connected in series. So motor will run if start
button is pushed, stop button is not pressed, overload relay is not picked and limit switch
is closed
PLC conveyer motor ladder logic
PLC conveyer motor ladder logic
Objective :  The sequential tasks as follows
1. When START button pressed
2. Motor will be started
3. RUN (Green Lamp) indication lamp will be activated
4. Motor Running, so Box will start Move
5. Proximity Sensor will detect when the box arrives at other end
6. Motor will be stopped
7. RUN (Green Lamp) indication lamp will be de-activated
8. STOP (Red Lamp) indication lamp will be activated
9. An Emergency Stop push button will be used to stop the motor at any time
Relay Schematic 
….continued
 R : STOP Indication lamp,
 G : RUN Indication lamp,
 M : Motor,
 OL : Overload Relay (Motor Protection Relay),
 LS1 : Proximity Switch,
 PB1 : Start push button,
 PB2 : Emergency Stop Pushbutton,
 CR : Contractor Relay
Operational Sequence 

 Start button is actuated.

 CR1-1 closes to seal in CR1 or to latch the start command
 CR1-2 opens, switching the red stop pilot light off
 CR1-3 closes, switching the green run pilot light on
 CR1-4 closes to energize the motor starter and motor
 The box/package moves, and proximity switch (LS1) detects the box when it reached and de-energize
coil CR1
 CR1-1 opens to open the seal-in contact ( unlatched start command)
 CR1-2 closes, switching the red pilot light on
 CR1-3 opens, switching the green pilot light off
 CR1-4 opens to de-energize the starter coil, stop the motor, and end the sequence
PLC Ladder Logic
PLC program for Forward reverse motor control
 In this case we need to operate motor in both direction, that can be possible only by
forward/Reverse Control Relay Circuit or through Logic.
 Here we solve this problem by using simple Forward/Reverse Control Logic in the PLC.
 So here we will consider one 3 phase motor for Forward and Reverse Operation.
 And we will take two contactors or relays for motor control because we need two different
directions here i.e. Forward/Reverse. First contactor for Forward Direction control and
Second contactor for Reverse Direction control of Motor.
 Also we should consider three push buttons i.e. for forward, reverse and stop functions of
motor.
 So here operator will use FWD PB for forward operation, REV PB for reverse operation and
STOP PB for stop function
PLC Inputs List
 FWD PB : I1
 REV PB: I2
 STOP PB : I3
 Motor Trip relay : I3

PLC Outputs List

 Motor forward : M1
 Motor reverse : M2
 This circuit is also known as Forward/Reverse control for 3 Phase 
Induction Motor.
 We will write logic for forward condition in Network 1. Here we use the NO
contact of FWD PB (I1) for forward operation of the motor, we are using
push button so we need to use one NO contact of motor forward output coil
(M1) for latching purpose. (Push button only provides momentary contact
and we need to latch the action so motor forward coil contact will be used)
 Put NC contact of motor reverse output (M2) in series for unlatching the
circuit because both forward and reverse should not run at the same time.
• Put NC Contact in series in both network so operator can stop forward
or reverse rotation by pressing STOP PB(I3).
• Here we have used OLR for Protection of motor so add NC contact of
Motor trip (I4) in series in both the network for motor protection.
• Now write the logic for reverse condition in network 2. Here we will take
NO contact of REV PB (I2) for motor reverse function and also take one
more NO contact of the motor reverse output coil(M2) for latching the
motor reverse output (M2). (Push button only provides momentary
contact and we need to latch the action so motor forward coil contact will
be used.
• Here also put NC contact of motor forward output coil (M1) in series for
unlatching the circuit because both forward and reverse should not run
at the same time.
List of Inputs/Output
Inputs List
 Start PB : I1
 Stop PB: I2

Outputs List
 Motor 1: Q1
 Motor 2 : Q2
 Motor 3 : Q3