Technical Seminar Effective solutions for motor starting and protection

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Technical Seminar Effective solutions for motor starting and protection presents about IEC Standard and Motor Starting Methods; effective solutions for motor starting and protection motor protection agenda; motor protection manual motor starters ms132 rated ultimate short circuit breaking capacity; main electrical parameters of motors and somethings else.

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Nội dung Text: Technical Seminar Effective solutions for motor starting and protection

IEC Standard & Motor Starting Methods ABB Low Voltage Products, HCMC Technical Seminar Effective solutions for motor starting and protection © ABB Group © ABB Group April 17, 2015 | Slide 1 April 17, 2015 | Slide 3 Effective solutions for motor starting and protection Motor Protection Agenda Rated short-circuit breaking capacities § 9:00 – 9:15 welcome and safety briefing § 9:15 – 10:00 IEC Standard and Motor Starting Methods § 10:00 – 10:15 coffee break § 10:15 – 11:00 Softstarter - PSTX § 11:00 – 11:15 coffer break § 11:15 – 12:00 Contactor – AF Technology § Rated short-circuit breaking capacities are defined in the IEC 60947-2 Low-voltage switchgear and controlgear – § 12:00 – 12:15 Q&A part 2: Circuit-breakers § The rated short-circuit breaking capacities are stated as: § rated ultimate short-circuit breaking capacity (Icu) § rated service short-circuit breaking capacity (Ics) © ABB Group © ABB Group April 17, 2015 | Slide 2 April 17, 2015 | Slide 4 1
Motor Protection Manual Motor Starters MS132 Rated ultimate short-circuit breaking capacity (Icu) Short-circuit protection - Ratings § The rated ultimate short-circuit breaking capacity of a Manual Motor Starter is the value of the short-circuit current the Manual Motor Starter is able to break twice (according to the sequence of O – t – CO cycle) at the corresponding rated operating voltage. § The Manual Motor Starter not required to carry its rated current after the opening and closing cycle. Ics (Rated service short-circuit breaking capacity) Example: 25A, 400V, required rating: 50kA à no backup fuse required until 50kA short circuit withstand 25A, 400V, required rating: 60kA à backup fuse must be 100A © ABB Group © ABB Group April 17, 2015 | Slide 5 April 17, 2015 | Slide 7 Motor Protection Manual Motor Starters MS132 Rated service short-circuit breaking capacity (Ics) Trip Curves diagrams § < 1.05 IN = No tripping § Test of rated service short-circuit breaking capacity § 1.05 Ir < IN < 1.20 tripping § The sequence of operations shall be: O – t – CO – t – CO thermal tripping within 2 hours § The rated service short-circuit breaking capacity of a Manual Motor Starter is the current value the Manual Motor Starter is § 14 x IN = magnetic tripping able to break three times according to a cycle of opening, pause +/-20% and closing operations (O - t - CO - t - CO) at a given rated service voltage. § After this cycle, the circuit-breaker must be able to carry its magnetic rated current. tripping O – t – CO – t – CO test condition The initial test setup is that there is a manual motor starter in series with breaker and the manual motor starter is in an ON position. Than the breaker is closed on a high current onto the MMS. The MMS trips and it is in OFF/TRIP Position. In other words the manual motor starter will trip and will close again and trip on the fault two times. © ABB Group © ABB Group April 17, 2015 | Slide 6 April 17, 2015 | Slide 8 2
Manual Motor Starters MS132 Manual Motor Starters MS132 Thermal trip diagrams Trip Tolerances Tolerances § Thermal curve is tested from Ir = Setting Current 3 x In … 7,2 x In § Standard with +/- 20% tolerance § Tripping curves are standardized in classes acc to IEC 60 947-4.. Class 30: 9 - 30 s Class 20: 6 - 20 s Class 10: 4 - 10 s § Electromagnetic curve is tested Motor Class 10A: 2 - 10 s with +/- 20% tolerance curve 7.2 Ir Example 3 © ABB Group April 17, 2015 | Slide 9 © ABB Group April 17, 2015 | Slide 11 Tolerance Statement Manual Motor Starters MS132 Main electrical parameters of motors Original Trip Curves Standard Trip Curves Motor data: Starting parameters from the ABB library or to find in Internet In accordance to the IEC 60947 - 4 - 1 standard the starting current is defined as: Designed with simple curve without tolerance field I a = 7.2 x Ie Thermal trip curve With reference to the characteristics of the most common motors is given a value for the typical maximum initial starting current defined as: Magnetic trip curve Ip = 12 x Ie © ABB Group © ABB Group April 17, 2015 | Slide 10 April 17, 2015 | Slide 12 3
Main electrical parameters of motors Motor Protection Motor branch and coordination § With reference to the starting typical current waveform of the motor (in red) the previous parameters (Ie – Ia – Isp) are drawing as below: - Disconnector ISOLATE - Switch Disconnector Ie = Rated nominal current PROTECT - Switch Fuse t [s] AGAINST - Circuit Breaker (Magnetic) Ia = Rated starting current (7.2 x In) SHORT-CIRCUIT - Manual Motor Starter Ip = Maximum peak inrush current CONTROL - Contactor (12 x In) PROTECT AGAINST - Thermal Overload relay OVERLOAD - Electronic overload relay M Ie I [A] 3~ Ia=7.2xIe Ip=12xIe © ABB Group © ABB Group April 17, 2015 | Slide 13 April 17, 2015 | Slide 15 Motor Protection Magnetic only circuit breaker Coordinations in a System § It allows to have a magnetic trip threshold I3 (up to 13 times In) higher than standard releases with value of 10 x In. Importance of Motor protection § Assure protection of people and assets / installations § This allows to face better the possible problems linked to the particularly high whatever the current levels may be reached: in rush current of the motor during the first instants of its starting phase. BOTH NEEDS overload or short-circuits LEADS TO COORDINATION § Keep production running with high availability § To this purpose can be used the molded case circuit-breakers Tmax series BETWEEN THE DIFFERENT PARTS § Reduce service costs in case of trouble or the miniature circuit-breaker such as the MO325. / PRODUCTS OF A MOTOR within decreasing operating durations SWITCHGEAR. and replacement costs of products § STANDARDS : IEC 60947-4-1 (Contactors and Starters) © ABB Group © ABB Group April 17, 2015 | Slide 14 April 17, 2015 | Slide 16 4
Contactor Motor Protection § It is the device intended to carry out the switch on/switch off operations of the Motor branch and coordination motor under normal conditions and also to disconnect the motor from the supply network in case of overcurrents detected by the thermal relay which commands the tripping. Short Short § The contactor shall be chosen so as to be suitable to carry the rated current of Circuit Circuit MO… the motor with reference to the category AC-3. Short MMS + + Typically, the contactor allows an electrical life higher than the circuit-breaker. Circuit § Overload Overload Protection Protection Protection + Switch Control Control Overload Protection © ABB Group © ABB Group April 17, 2015 | Slide 17 April 17, 2015 | Slide 19 External overload relay Why to get a good coordination? Coordination – Service Levels § It is the device intended to Coordination type 1 Coordination type 2 realize the protection against find by tests find by tests motor overload and it has usually the function of commanding the opening of § No risk for operators or § No risk for operators or the contactor for those installations installations overcurrents lower than the § Isolation is kept after inrush § Isolation is kept after inrush magnetic trip threshold of the circuit-breaker. § Before re-starting, starter § The starter is still working repairing is necessary after short-circuit § Other apparatus than § Before re-starting, a quick contactor and overload inspection is sufficient relay shall not be damaged § Light welding of contacts is allowed if they could be easily separated (by electrical operation or tool) © ABB Group © ABB Group April 17, 2015 | Slide 18 April 17, 2015 | Slide 20 5
Coordination types The Tripping Class Depending from the condition of the contactor and the thermal overload release after the short circuit test according to IEC 60947-4-1 Standard. Coordination type Type 1 = Damages to the contactor and to the overload relay are acceptable. Class 10 A 10 20 30 The starters may be inoperative after each operation. Therefore the starter shall be inspected and the contactor and/or the overload relay and the release Tripping at 7.2 x In (sec.) 2..10 4..10 6..20 9..30 shall be replaced if necessary. There shall not be damages for the users. Type 2 = No damages to the overload relay or other parts have occurred Tripping at 1.5 x In (m) 2 4 8 12 except that welding of contactor or starter contacts which is permitted, if they are easily separated without significant deformation. Tripping at 1.2 x In (h) £2 Comparison Tripping at 1.05 x In (h) never ÜType 1 initial economic advantage - expensive maintenance - stops of the plant due to faults. ÜType 2 initial high investment - service continuity and quality - easy maintenance. © ABB Group April 17, 2015 | Slide 21 ABB SACE The tripping class The tripping class curves The Standard gives the following classification for the main tripping classes: Class 10A – 10 – 20 – 30 § A Mills This classification refers to the characteristics of the thermal protection. In particular, for the current value of (7.2 x Ie), the range of the tripping time for the different classes is indicated § B Fans coil as below: § C Pumps } Usually called Normal Start-up type: Class 10A 2s
Curves showing the electrical life for the category AC-3 Thermal overload releases characteristics The utilization category is defined by the Standard with reference to the characteristics and to the application of the motors. AC-3 is the most common utilization category, and it is referred to the squirrel-cage asynchronous motors for starting and switching off motors during running. © ABB Group © ABB Group April 17, 2015 | Slide 25 April 17, 2015 | Slide 27 Contactors series A-AF characteristics Motor starting current With reference to the threshold curve of the magnetic protection and the thermal protection is possible to realize a solution with the characteristics given in the picture. The starting current of the motor is always under the tripping curve of the protection devices (thermal and magnetic) in order to permit the start of the motor. t [s] Thermal protection Tripping Class Motor starting Magnetic current thereshold Ie I [A] Ia=7.2xIe Ip=12xIe © ABB Group © ABB Group April 17, 2015 | Slide 26 April 17, 2015 | Slide 28 7
Complete coordination tables The electrical asynchronous motor (more than 160 tables) Mechanical design § Electrical coordination in accordance with IEC 60947- Terminal box 4-1, contactors and motor-starters, UL 508 (USA) § Complete coordination tables Drive shaft § Breakers and fuses § Type 1 and 2 according to IEC 60947 Cooling fan http://applications.it.abb.com/SOC direct adress www.abb.com/lowvoltage Tools Coordination tables Stator windings Rotor Stator © ABB Group © ABB Group April 17, 2015 | Slide 29 April 17, 2015 | Slide 31 Motor Protection The electrical asynchronous motor Coordinations in a System What makes the speed different? Motor data: Rated parameters Synchronous speed at: Synchronous speed P = Rated motor power [kW] Poles 50 Hz 60 Hz 2 * f * 60 n1 = 2 3000 3600 V = Supply voltage [V] p 4 1500 1800 cos j = Power factor 6 1000 1200 h = Efficiency Rotor speed 8 750 900 10 600 720 Ie = Rated current [A] n2 = n1 * (1 - s) P 12 500 600 Ie = 14 375 450 h ´ cosj ´ 3 ´V • • p f Number of poles. Frequency. 16 300 360 • s Slip. • n1 Synchronous speed • n2 Rotor speed © ABB Group © ABB Group April 17, 2015 | Slide 30 April 17, 2015 | Slide 32 8
The electrical asynchronous motor Motor starting methods Typical motor characteristics Direct on-line T Tst/Tn 1,5…2,5 High inrush current High torque during start § Traditional starting method Contactor § Full voltage with no control Tn of the start § Combinations for motor n protection I 7*In § Compact and cost efficient solution Thermal overload In (FLA) § Mostly used for small relay motors n Nominal speed © ABB Group © ABB Group April 17, 2015 | Slide 33 April 17, 2015 | Slide 35 The electrical asynchronous motor Motor starting methods Common problems when starting & stopping Direct on-line § Slipping belts Potential electrical Potential mechanical § Heavy wear and tear on problems problems couplings, gear boxes § Voltage drops § Slipping belts and bearings § Tripping breakers § Heavy wear and tear § Damaged products § High starting current § Pressure surges and water hammering in pipe 16 * In systems § Damaged material and products 8 * In Torque 1,5 - 2,5 * Tn Current In Tn Motor speed Motor speed © ABB Group © ABB Group April 17, 2015 | Slide 34 April 17, 2015 | Slide 36 9
Motor starting methods Different starting methods Direct on-line Auto-Transformer-start Light load Medium load Heavy load § Three different current Contactors levels § Transmission peaks at loaded start § Three starting torque levels T T T Thermal § Always direct stop overload relay § High price § Big rpm rpm rpm I I I Transformer rpm rpm rpm © ABB Group © ABB Group April 17, 2015 | Slide 37 April 17, 2015 | Slide 41 Motor starting methods Different starting methods Star delta starter Auto-Transformer-start § Lower starting current than Transmission DOL for light loads peaks T T T § Low starting torque 80% 80% 80% § Transmission (torque) 65% 65% 65% 50% 50% 50% peaks at loaded start rpm rpm rpm § Complex wiring with many Contactors Low load High load Medium load devices & double motor I Current peaks cables 80% Timer 65% 50% Thermal overload relay rpm © ABB Group © ABB Group April 17, 2015 | Slide 38 April 17, 2015 | Slide 42 10
Different starting methods Different starting methods Partwinding start Slipring motor starter Contactors • Medium high starting § Low starting current current § Transmission peaks at M • Transmission peaks at loaded start Changing the loaded start § High starting torque rotor resistance • Low starting torque (adjustable) T (often too low) § Medium long starting • Medium long starting time time • Always direct stop § Always direct stop § Motor not designed for use with modern starters Very low starting Thermal torque at zero / Too low starting torque. Overload speed With shorted relay rotor rpm © ABB Group © ABB Group April 17, 2015 | Slide 43 April 17, 2015 | Slide 45 Different starting methods Motor starting methods Partwinding start Variable speed drives T T Transmission § Full control of speed, T peaks current and torque § Energy saving from reducing speed rpm rpm rpm Low load High load Medium load § Mostly used for process Too low control I starting torque Contactor Current peaks VSD rpm M © ABB Group © ABB Group April 17, 2015 | Slide 44 April 17, 2015 | Slide 46 11
Motor starting methods Motor starting methods Variable speed drives Softstarter § Modifies the the frequency § Soft start and stop of full § Rated current and torque speed applications from start § Reduced starting current Line AC Contactor DC T § Reduced starting torque DC § Reduced acceleration Softstarter AC § Minimized mechanical wear Built in Electronic M overload Built in M rpm © ABB Group © ABB Group By-pass April 17, 2015 | Slide 47 April 17, 2015 | Slide 49 Motor starting methods Motor starting methods Variable speed drives Softstarter U I Concerns 100% § High investment cost § Large and heavy § Creates harmonics U = 50% I = 50% § No bypass at full speed § Heat dissipation § Speed regulation not always suitable t rpm § No value for full speed application T speed T = 25% time rpm © ABB Group © ABB Group April 17, 2015 | Slide 48 April 17, 2015 | Slide 50 12
Motor starting methods Softstarters Softstarter How we have helped the industry Light load Medium load Heavy load 60% 20% 100% T T T 60% lower starting 20% smaller panel. 100% increased current. Increasing Lower installation lifetime. Reduced rpm rpm rpm motor lifetime. cost. maintenance cost. I I I Securing motor reliability at Rhoss. rpm rpm rpm © ABB Group © ABB Group April 17, 2015 | Slide 51 April 17, 2015 | Slide 53 Softstarters Secure motor reliability Three types of current limit Start your motor with full control of current - also in weak networks Softstarter - PSTX Motor heating Keep your motor running reliably even in cold and humid environments Complete motor protection Keep your motor safe from load and Secure motor network abnormalities Reliability © ABB Group © ABB Group April 17, 2015 | Slide 52 April 17, 2015 | Slide 54 13
Secure motor reliability Secure motor reliability Three types of current limit Complete motor protection Start your motor with full control of current Keep your motor safe from load and network abnormalities - also in weak networks I § Load protections: § Current limit § Over load protection § Define a maximum § Under load protection starting current. § PT100 / PTC rpm I § Network protections: § Dual current limit § Over voltage § Change current limit § Under voltage level during start. § Earth fault rpm I § … or define your own protection § Current ramp § Increase the current limit gradually. rpm © ABB Group © ABB Group April 17, 2015 | Slide 55 April 17, 2015 | Slide 57 Secure motor reliability Secure motor reliability Motor heating Underload protection Keep your motor running reliable even in cold and humid environments § Remove condensation in idle motors. § Prevent freezing of the motor. § Perfect for humid installations and cold environments. © ABB Group © ABB Group April 17, 2015 | Slide 56 April 17, 2015 | Slide 58 14
Softstarters Improve installation efficiency How we have helped the industry Detachable keypad Control your process and softstarter safely 60% 20% 100% 60% lower starting 20% smaller panel. 100% increased current. Increasing Lower installation lifetime. Reduced motor lifetime. cost. maintenance cost. § Graphical display § IP66 & 4x outdoor Improving installation § Assistants for fast and easy set-up efficiency at Tianjin Qihaixin. § 15 languages © ABB Group © ABB Group April 17, 2015 | Slide 59 April 17, 2015 | Slide 61 Softstarters Improve installation efficiency Improve installation efficiency Built-in bypass Reduce energy consumption at full speed – preinstalled Detachable keypad Control your process and softstarter safely Built-in bypass Reduce energy consumption at full speed – preinstalled Flexible communication § Reduces energy consumption at full speed One product meeting all communication § Increases life time of softstarter Improve installation requirements § Reduces heat dissipation Efficiency § All protections are available in bypass mode § Already installed and verified © ABB Group © ABB Group April 17, 2015 | Slide 60 April 17, 2015 | Slide 62 15
Improve installation efficiency Softstarters Flexible communication How we have helped the industry One product compatible with all communication requirements 60% 20% 100% Built-in Anybus-CC FBP adapter (retro fit) 60% lower starting 20% smaller panel. 100% increased Modbus RTU Modbus RTU Modbus RTU current. Increasing Lower installation lifetime. Reduced motor lifetime. cost. maintenance cost. ProfiBus DP ProfiBus DP DeviceNet DeviceNet Increasing application productivity at ZAO VIV Modbus TCP Modbus TCP and A-Trade. EtherNet/IP © ABB Group © ABB Group April 17, 2015 | Slide 63 April 17, 2015 | Slide 66 Improve installation efficiency Softstarters Approvals and certificates Increase application productivity A global product ready to be used all over the World Available today Limp mode & coated PCBA Do only planned stops for increased productivity Motor jog Increase process flexibility with application specific features Pending Pump control Increase lifetime of your pump system Increase application Productivity © ABB Group © ABB Group April 17, 2015 | Slide 65 April 17, 2015 | Slide 67 16
Increase application productivity Increase application productivity Limp mode & coated PCBA Torque control Do only planned stops for increased productivity Increase equipment lifetime by eliminating water hammering Voltage ramp Torque control STOP signal STOP signal speed speed time time § Keep running with one shorted thyristor § Do service when you have time § Protections and main features are still functioning § Coated PCBAs are protected from harsh environments § Reducing pump speed linearly for complete control § Avoiding water hammering and pressure surges © ABB Group © ABB Group April 17, 2015 | Slide 68 April 17, 2015 | Slide 70 Increase application productivity Increase application productivity Motor jog Torque control Increase process flexibility with application specific features § For positioning and maintenance inspections § Forward and backward § Three speed levels § Controlled from keypad or digital inputs © ABB Group © ABB Group April 17, 2015 | Slide 69 April 17, 2015 | Slide 71 17
Increase application productivity Increase application productivity Pump cleaning Anti-backspin Use the softstarter to clean the pump Full control of air flow ? Forward speed time Backward speed Fan 1 Fan 2 Fan 1 Fan 2 § For jammed or clogged pumps (e.g. waste water) § Kick-start forward and slow speed reverse § Controllable from digital inputs © ABB Group © ABB Group April 17, 2015 | Slide 72 April 17, 2015 | Slide 74 Increase application productivity Increase application productivity Pump cleaning Anti-backspin © ABB Group © ABB Group April 17, 2015 | Slide 73 April 17, 2015 | Slide 75 18
Increase application productivity Anti-backspin Full control of air flow Contactors – AF Technology STOP Fan 1 Fan 2 Fan 1 Fan 2 § Prevents the motor from rotating § Parallel installations, windy conditions, over pressure § Instead of mechanical lock © ABB Group © ABB Group April 17, 2015 | Slide 76 April 17, 2015 | Slide 78 Softstarters Technical presentation Our offering Content § Introduction § AF technology § Access global support § Optimize logistics § Simplify design § Secure uptime PSR – The compact range PSE – The efficient range PSTX – The advanced range • basic and simple • the perfect compromise • the complete alternative • smaller sized motors • small and medium sized motors • medium and large sized motors • many starts per hour • designed for pump applications • for every application © ABB Group © ABB April 17, 2015 | Slide 77 17 April 2015 | Slide 79 19
The latest technology – already our standard The latest technology – already our standard The new AF contactor range The complete AF contactor range Width in mm 45mm 45mm 55mm 70mm 90mm Type AF09 AF12 AF16 AF26 AF30 AF38 AF40 AF53 AF65 AF80 AF96 AF116 AF140 AF146 Rating AC-1 (A) 25 28 30 45 50 50 70 100 105 125 130 160 200 225 AC-3 (kW) 4 5,5 7,5 11 15 18,5 18,5 22 30 37 45 55 75 75 (hp) 5 7,5 10 15 20 20 30 40 50 60 60 75 100 100 105mm 140mm 186mm 210mm 438mm Type AF190 AF205 AF265 AF305 AF370 AF400 AF460 AF580 AF750 AF1250 AF1350 AF1650 AF2050 AF2650 Rating AC-1 (A) 275 350 400 500 600 600 700 800 1050 1260 1350 1650 2050 2650 AC-3 (kW) 90 110 132 160 200 200 250 315 400 - 475 560 - - (hp) 125 150 200 250 300 350 400 500 600 - 800 900 - - © ABB © ABB 17 April 2015 | Slide 80 ABB block contactors overview The latest technology – already our standard Technical presentation Complete product offering Content § Introduction MOTOR CONTROL POWER DISTRIBUTION CONTACTORS § AF technology 9A 1050A AC-3 § Access global support 2650A § Optimize logistics AC-1 22A SCPD § Simplify design MCCB 9A 1050A § Secure uptime ACB/MCCB 22A 2650A MMS 0,1A 100A Overload relays Thermal 0,1A 200A Electronic 0,1A 1050A © ABB © ABB 17 April 2015 | Slide 81 17 April 2015 | Slide 83 20