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Questions about starting electric motors are common. Motor starting problems resulting from these questions can be costly and
confusing, leading to production delays and sometimes catastrophic motor failure. This article will briefly explore some of the most
common questions about the direct online (DOL) starting of squirrel cage induction motors. Through proper application, end users
can have confidence that their motors and related equipment will not incur damage during the starting cycle.
Key performance information related to motor starting is shown on speed-torque-current plots. In Image 1, the intersection of the
torque curve at zero speed will show locked rotor torque (LRT), while the maximum torque value shown represents breakdown
torque (BDT). Both full load torque (FLT) and current levels (FLC/FLA) are found by drawing a vertical line from the rated speed
point until it intersects both plots. The point on the current plot corresponding to zero speed will show locked rotor current
(LRC/LRA), while the motor’s no load current (NLC/NLA) is shown by the point corresponding to the highest speed shown.
If shown separately, the “cold” curve provides the safe locked rotor times for the motor when it is first started (the “cold” condition),
while the “hot” curve provides the safe stall times after a motor has either been recently started or run under load. It should be noted
that Image 2 only shows a single plot connecting the safe stall time plots in cold condition with the “overload” curve. The safe stall
time plots should never overlap or come substantially close to the motor accelerating current plots, as this represents dangerous
heating in the rotor bars and end rings.
The overload curve shows the time that a motor can safely operate while running at, or above, full-load current. Typically, the upper
bounds of this curve correspond to a continuous time associated with the motor’s highest safely rated load level (often the service
factor). If this plot is followed to higher levels of current (and therefore lower values of time), it will often be plotted to intersect the
safe stall time curve(s), but most often is shown to just nearly intersect them.
LRC decreases in basically direct proportion with voltage, while LRT decreases as approximately voltage squared and can quickly
cause starting issues for processes that start under load. Careful coordination between the end user and motor supplier is required
to ensure that a proper motor design is selected for both onsite conditions and the load’s profile to provide reliable, safe locked rotor
performance.
There are several methods available for estimating acceleration time, but all methods must begin with the motor and load’s speed-
torque curves and total inertia. The most basic method divides the speed torque characteristics up into equal intervals (typically
somewhere around 10 as shown in Image 3) and finds the net accelerating torque available during that period to calculate its
individual contribution to acceleration time. Net accelerating torque is defined as the load torque subtracted from the motor torque at
a given point (generally the motor torque should be at least 10 percent greater than load torque). Once net accelerating torque and
time have been found for all intervals from zero speed to full-load speed, the times in seconds are added to provide total estimated
acceleration time. For every interval, the total inertia (motor and load reflected to motor shaft) must be accounted for, as high inertia
loads (e.g. large centrifugal fans) can lengthen acceleration times.
Finally, similar to locked rotor performance, voltage dip and recovery must be considered, as they will reduce motor torque available
and thus increase total acceleration time.
a motor’s rated KVA Code Letter (assigns a “code letter” defined by NEMA MG-1 that gives an idea of the motor’s locked
rotor current level when compared to its rated hp)
how to interpret a large motor’s acceleration nameplate information (for example, understanding what the number of hot and
cold starts means and how to interpret the time required between them)
the theory behind safe locked rotor times and how these values are derived (principally these are based on the amount of
time anticipated for critical motor components like rotor bars, end rings and stator windings to reach damaging temperatures)
With this information, end users and those involved in specifying induction motors can confidently operate and select motors for
various starting scenarios. Note: this article has been written with squirrel cage induction motors in mind, most of these concepts
are applicable to other motor types, including wound field synchronous (with squirrel cage rotor windings) and wound rotor induction
motors.