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Soft Starter In Industrial Applications

Danfoss VLT Soft Starter - Applications like pumps, conveyers, centrifuges and bandsaws must
be started slowly, and sometimes stopped slowly, to prevent mechanical shocks such as water
hammer, and strains on bands, couplings and shafts

Introduction to Soft Starter

An induction motor connected directly to the power supply draws a constant magnetizing current at full
speed, no matter what the load is. At anything less than full load, power factor of the induction motor is
less than its rated power factor because the torque producing current decreases as the load

decreases, but the magnetizing current does not change. The lighter the load, worse the power factor.
Motors selected from a standard range are almost always chosen with a rated power in excess of
maximum load demand, with the result that in any installation the motors seldom operate at their full
rated load. Consequently, they can never achieve their rated power factor even at a maximum load
demand. More over, if the load is variable.
The wastage of energy is worse Electrical energy supply tariffs for industrial users almost invariably
carry a heavy penalty i.e.; higher cost per unit- for consumption at low power factors. Further, the cost
charged is increased if demand exceeds a maximum limit.
The AC induction motor with a permanently coupled load, when it is operated without the benefit of a
soft starter draws a high starting current. Typically, more than 7 times its rated full load current.
Reduced voltage-starting decreases the demand. A Soft starter makes use of this principle.
The mechanical shock delivered to the rotor or to couplings or to any intermediate gearing and the
driven load by a high starting current is most severe when the motor is started directon-line. Even
reduced voltage starting devices like the star delta starter or Auto transformer starters still impose
shock loads because of the very current peaks which cause severe transient torques at the moments of
intermediate switching.
The effect of such repeated shocks is to decrease the life of the motor and increase the cost of
maintenance.

Soft Starter Construction

The Flux compensated magnetic amplifier (FCMA) Soft starter essentially consists of predominantly
inductive impedance in series with the motor windings to control the motor current through a potential
divider.
Finally when the motor
has reached full speed
and the motor terminal
voltage has reached
around 90-96% a
shorting device cuts the
Mag Amps out of the
motor circuit and the
motor runs under
normal operating
conditions.

Inductive impedance in series with the motor windings

Constructionally the
Flux compensated
magnetic amplifier is
an extremely
rugged device
comprising of magnetic
core and amply sized
power windings. It
should be emphasized
that there is no external
control loop on the
Inductive impedance in series with the motor windings with shorting device
system and impedance
variation is the natural
characteristic of the
system achieved through suitable winding design and geometry.
This leads to 100% reliability of the operation.

Working principle
Conventionally the magnetic amplifiers have been equated with saturable core reactors, which work on
the principle of superimposition of magnetic fluxes in the additive mode thereby saturating the
magnetic core & varying the impedance .These have found limited usage in alternating current circuits
because they require D.C. excitation & generate a heavy percentage of harmonics in the current
waveform due to core saturation.
The Flux compensated magnetic amplifier (FCMA) is an antithesis of the saturable core reactor. The
FCMA works on the principle of flux opposition instead of flux addition & hence operate always in the
linear nonsaturable zone of the magnetic circuit. Oppposing flux linkages are impressed on the same
magnetic circuit, thus reducing total flux & hence reducing the impedance.
Total flux linkage = main flux linkage opposition flux linkage
N I = N1*I1 N2*I2
The system is designed to provide a predetermined constant current in the motor windings in the
starting zone. The main flux is generated by the current in the motor winding and the opposing flux is
generated by the counter emf of the motor as the motor speed increases. The net flux thus reduces,
allowing the motor voltage to rise gradually form as low as 50% to 96% while keeping the current within
the prefixed limit, thus efforting a smooth start. In fact the reduced start current allows closer calibration
of the protective relays.
The FCMA Soft starter achieves this through a unique system of flux compensated non saturated
magnetic amplifier for controlling the motor current and hence the motor torque during acceleration.

Main features of Soft Starter

These are the main features and benefits of soft starter:
1. Fastest payback period

2. Avoids fluid hammer

3. Easy to install
4. In built protection
5. Designed for extreme operating conditions
6. Programmable current and torque limits
7. Programmable acceleration and deceleration ramps
8. Two set point current limits
9. Instantaneous protections

The soft starting sequence

A Soft starter normally operates in three distinct stages:
Ramp
Dwell period
Energy Optimizing
These operating stages are as shown in figure below:
The
Ramp
stage
A. For
Open
loop

Soft starter operating stages

Configuration
From the instant that the start command is given, the system first imposes a fixed delay (3 to 300/500
ms) for self monitoring, and then causes a voltage to be applied to the motor terminals to achieve the
break-away torque.

This is the pedestal voltage in the figure below. This voltage is then ramped up linearly providing a step
less increase of motor terminal voltage from the pedestal upto the maximum voltage. At the end of the
ramp period the motor terminal voltage is equal to the input power supply voltage. As a standard the
pedestal voltage is 40% of the supply voltage. This can however be changed to suit desired
applications.
The current drawn by any motor accelerating from the rest position in an open loop configuration
depends upon the selected ramp. Shorter the ramp time, greater the peak starting current. Why choose
one ramp time rather than another?
For
every
motor
and
driven
load

Pedestal voltage; Top: Long ramp; Bottom: Short ramp

system, there is a natural ramp at which the acceleration of the load and the motor matches the rate of
increase of the output voltage of the soft starter. Selecting a short time will increase the rate of
acceleration and the starting current drawn; a longer time will prolong the time before the load reaches
the full speed, and will reduce the starting current.
This may be an advantage depending upon the particular application and perhaps on what
is convenient for matching with related process equipment.

B. Closed loop Configuration

This configuration of the Soft starter is used in applications where the driven load has a particularly high
inertia else it is difficult to start. For example, in a stir application where the medium is glutinous and
stiff at the beginning of the process.
The acceleration time of such loads is apt to lag behind the rate of rate increase of ramp voltage even if
a long ramp time is chosen. With such loads it may however be necessary to select short ramp time to
ensure sufficient starting torque. A short ramp will raise the voltage quickly but the nature of the load
prevents the motor speed matching it. The result may be excess current demand.
This problem is over come by a current limit feature which stops the ramp when the current output
reaches a pre-selected limit. The ramp is then held until the current falls naturally. The current limiting
feature is active only during the ramp period of the soft start sequence. Closed loop control requires
continuous measurement and feed back of the current delivered to the motor terminals by using a CT.

The Dwell period

The dwell period begins when the output voltage reaches maximum and this period is equal to the
selected ramp time, approximately equal to 10 seconds.
The dwell period maintains a constant voltage at maximum to allow the time for the motor and its driven
load to settle to a steady state after acceleration is complete and before the Soft starter automatically
enters the energy optimizing mode.

The optimizing stage

The energy optimizing stage is the normal operating condition of the Soft starter when the motor is up
to rated speed and driving the load at whatever torque output is demanded. The energy optimizing
stage is continuous after the dwell period until a stop command is given.
During the ramp period the system computes a reference value of the power factor. For energy
optimizing this value is continuously compared with the running power factor. From the comparator
output the system continuously computes, adjusts and updates the firing points of the thryistors so that
the total energy delivered to motor corresponds to the load torque demand without wasting energy in
overfluxing the motor. The power factor at the supply terminals is in this way maintained at the highest
possible value for every condition of the load demand.
Management of the power factor in no way detracts from the capability of the motor to respond to the
load demand .The motor performance is unaffected. This feature of the Soft starter is a purely electric
function which has the effect of ensuring that at all times the motor delivers the torque demanded, but is
allowed to draw only the precise amount of magnetizing current required to support the torque output.
Without this feature, the motor would draw a maximum magnetizing current regardless of the load.
The effect of the energy optimizing function is a cumulative economy in energy consumption.

The Soft-Stop function

This is a unique feature of the Soft starter. Its effect is to prevent an undesirably sudden deceleration of
the load. It is useful in various mechanical handling and conveyor systems and in many hydraulic
pumping operations where a sudden removal of the drive input can induce undesirable effects, such as
the fluid hammer in the pipelines.
The soft stop ramp operates to reduce the motor terminal voltage down to 40% of maximum, at which
time, the thyristors are disabled. The motor and load will coast to standstill.

Comparison: Soft Starter and Auto Transformer Starter

A. Operational differences
Soft Starter

Auto Transformer Starter

Easy starting-by a push button.

Similar method of starting.

Motor starts without any jerks i.e. smoothly and

gradually picks up to the synchronous speed. The
life of the motor is thus increased significantly and
the maintenance problems are drastically reduced.

Motor is subjected to heavy jerks

during starting and a bit later because of
the sudden inrush of current .This causes
severe damages to the motor winding
which ultimately burn off.

The valve on the delivery side need not

be operated while switching the motor ON or OFF.

This is mandatory on both occasions i.e.

ON or OFF.

Soft starting and soft stopping avoids back thrust

on the NRV or the pipe line which is therefore
protected against the back thrust during switching
OFF.

Such a protection is not provided

and therefore, proper operation of the
valves is absolutely essential.

No electrical moving contacts and no oil hence no

sparking and hazards.

Circuitry consists of several moving

parts and hence sparking is unavoidable.

No limitations on the No. of starts and No. of stops

per hour.

Limited No of starts and stops per

hour because of: motor windings getting
heated.

Acceleration time for motor to speed up from rest

to rated full speed can be adjustable from 2 secs
to 90 secs. This will facilitate selection of
appropriate ramp times to suit the
desired load/torque requirements.

Such a facility is not available

with conventional timers used in this
method of starting.

In rush (starting) current restricted to 200% of rated

full load current (FLC).

Inrush current restricted to maximum

of 400% of the FLC.

B. Protections
Soft Starter

Auto Transformer Starter

Phase reversal, single phasing, overload, over voltage, under

voltage and short circuit are available.

Phase reversal and short

circuit protections not
available.

Current limit facility is available which limits the current drawn

by the motor plus the load to a desired safe value.

This facility is not available.

C. Economics
Soft Starter

Auto Transformer Starter

Approximately Rs. 15000/- to Rs. 50000/- per

annum, per equipment is saved by virtue of energy
saving. The exact amount of energy saved depends
upon the loading conditions.

Energy saving not achieved.

By using this the power factor can be improved by

.05 which will cost further saving and will also avoid
KEB penalties.

Provision for power factor improvement

not available.

Reduction of maintenance costs on account of:

This method of starting is prone to

all these problems occurring very
frequently and hence involves
tremendous expenses on maintenance.

- No necessity of transformer oil.

- No moving parts present (like contactors, relays
etc.).
- Motor fully protected and hence no rewinding costs.
Minimum down time.

Advantages of Soft Starter

Down time too large.

Soft starters are used on high tension motors for the following advantageous features:
1. Smooth starting by torque control for gradual acceleration of the drive system thus
preventing jerks and extending the life of mechanical components.
2. Reduction in starting current to achieve break-away, and to hold back the current
during acceleration, to prevent mechanical, electrical, thermal weakening of the electrical
equipment such as motors, cables, transformers & switch gear.
3. Enhancement of motor starting duty by reducing the temperature rise in stator windings
and supply transformer.
4. The microprocessor version of the Soft starter has a soft ware controlled response at full
speed which economizes energy, what ever may be the load. Because of the tendency to over
specify the motor rated power, this feature has benefits for most installations- not only those
where load is variable.
5. The power factor improvement is a self monitoring in built feature. When the motor is running
at less than full load, the comparative reactive component of current drawn by the motor
is unnecessarily high due to magnetizing and associated losses. Hence the voltage dependent
losses are minimized with the load proportional active current component and as a result the
power factor also improves simultaneously.

Areas of Soft Starter application

These are main applications of Soft starter:
Steel industries (Rolling mills and processing lines)
Cement industries
Sugar plants
Paper and pulp
Rubber and plastic
Textile industries
Machine tool applications
Power sector
Water supply scheme
And various process control applications

Conclusion
The starting performance of the squirrel cage induction motors using Soft starters provides valuable
economics of electrical energy .Optimum benefits are gained when a motor duty involves frequent start
or stop cycles but is still likely to be worth while in systems which are in continuous operation.
The word Soft starter has almost become synonymous to conventional starters.
Reference: Significance of soft starter in industrial applications by N.Mahesh and P.Vishnu (Aurora

Technological and Researc Institute)