Design And Construction Of Star And Delta Electric Motor Panel For A 5Hp Motor

Electrical Electronics Engineering | Industrial Physics | Physics

The design and construction of a star and delta electric motor panel for a 5Hp motor involves the creation of a control panel that facilitates the operation of the motor using either star or delta configurations, each suited for specific operational requirements. The panel comprises various components such as contactors, overload relays, circuit breakers, and control circuitry. In the star configuration, the motor windings are connected in a triangular shape, offering reduced starting current and higher torque at startup, suitable for applications demanding high torque during initial acceleration. Conversely, the delta configuration connects the windings in a closed loop, providing higher speed and power output, ideal for applications requiring constant speed operation. The panel design ensures seamless switching between the star and delta configurations, promoting operational flexibility and efficiency in diverse industrial settings. Additionally, safety features such as overload protection and emergency stop functionalities are integrated to safeguard both the motor and the operational environment, adhering to stringent safety standards and ensuring reliable performance throughout the motor’s lifespan.

ABSTRACT

This work is on star and delta electric motor starter panel for a 5hp (4kw) motor. Star-delta starting is achieved by physically reconfiguring the motor windings. During starting the motor windings are connected in star configuration and this reduces the voltage across each winding. This also reduces the torque by a factor of three. After a period of time the winding are reconfigured as delta and the motor runs

Star/Delta motor are probably the most common reduced voltage of the motor. They are used in an attempt to reduce the start current applied to the motor during start as a means of reducing the disturbances and interference on the electrical supply.

This work required to fit a reduced voltage starter on motors of 5HP (4KW). The Star/Delta (or Wye/Delta) starter is one of the lowest cost electromechanical reduced voltage starters that can be applied.

TABLE OF CONTENTS

COVER PAGE

TITLE PAGE

APPROVAL PAGE

DEDICATION

ACKNOWELDGEMENT

ABSTRACT

CHAPTER ONE

1.0 INTRODUCTION

1.1 BACKGROUND OF THE PROJECT

PURPOSE OF THE PROJECT
AIM OF THE PROJECT
OBJECTIVE OF THE PROJECT
PURPOSE OF THE PROJECT
LIMITATION OF THE PROJECT
ADVANTAGES OF THE PROJECT
PROBLEM OF THE PROJECT
APPLICATION OF THE PROJECT
RESEARCH QUESTION
PROJECT ORGANISATION

CHAPTER TWO

LITERATURE REVIEW

REVIEW OF MOTOR STARTERS
DIFFERENT TYPES OF AC MOTORS
REVIEW OF DIFFERENT TYPES MOTOR STARTER

CHAPTER THREE

3.0 CONSTRUCTION METHODOLOGY

3.1 STAR DELTA STARTER THEORY

3.2 WORKING PRINCIPLE OF STAR DELTA STARTER PANEL

3.3 COMPONENTS OF STAR DELTA MOTOR PANEL

3.4 CIRCUIT OPERATION OF THE PANEL

CHAPTER FOUR

CALCULATE SIZE OF CONTACTOR, FUSE, C.B, O/L OF STAR/DELTA STARTER
CALCULATION OF MOTOR TORQUE & CURRENT
SIZE OF FUSE
SIZE OF CIRCUIT BREAKER
THERMAL OVER LOAD RELAY

CHAPTER FIVE

CONCLUSION
RECOMMENDATION
REFERENCES

CHAPTER ONE

1.1 INTRODUCTION

An electric motor converts electrical energy into mechanical energy. The reverse of this would be the conversion of mechanical energy into electrical energy and is done by an electric generator.

In normal motoring mode, most electric motors operate through the interaction between an electric motor’s magnetic field and winding currents to generate force within the motor. In certain applications, such as in the transportation industry with traction motors, electric motors can operate in both motoring and generating or braking modes to also produce electrical energy from mechanical energy.

Found in applications as diverse as industrial fans, blowers and pumps, machine tools, household appliances, power tools, and disk drives, electric motors can be powered by direct current (DC) sources, such as from batteries, motor vehicles or rectifiers, or by alternating current (AC) sources, such as from the power grid, inverters or generators. Small motors may be found in electric watches. General-purpose motors with highly standardized dimensions and characteristics provide convenient mechanical power for industrial use. The largest of electric motors are used for ship propulsion, pipeline compression and pumped-storage applications with ratings reaching 100 megawatts. Electric motors may be classified by electric power source type, internal construction, application, type of motion output, and so on.

Electric motors are used to produce linear or rotary force (torque), and should be distinguished from devices such as magnetic solenoids and loudspeakers that convert electricity into motion but do not generate usable mechanical powers, which are respectively referred to as actuators and transducers.

Most induction motors are started directly on line, but when very large motors are started that way, they cause a disturbance of voltage on the supply lines due to large starting current surges. To limit the starting current surge, large induction motors are started at reduced voltage and then have full supply voltage reconnected when they run up to near rotated speed.

Voltage reduction during star-delta starting is achieved by physically reconfiguring the motor. During starting the motor windings are connected in star configuration and this reduces the voltage across each winding. This also reduces the torque by a factor of three.

The Star/Delta starter is manufactured from three contactors, a timer and a thermal overload. The contactors are smaller than the single contactor used in a Direct on Line starter as they are controlling winding currents only. The currents through the winding are 1/root 3 (58%) of the current in the line.

There are two contactors that are close during run, often referred to as the main contractor 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 (33%) of the motor rating.

Three phase star-delta motors are constructed similarly to a direct online single phase motor, but the terminals for each winding are not terminated within the motor, instead they are brought out of the motor for control wiring to connect to.

Three phase star-delta motors are used for maximum talk, where the motor will try to start under a heavy load. A star-delta motor starts in two stages, controlled by equipment connected to it.

The motor is required to start. To provide the maximum available torque, the motor is started in ‘star’, which provides a supply of 230volts to each of the windings (providing high current to each winding).

Once the motor is running, it is running in an inefficient mode, due to the use of a high current supply, which will (if left) cause the motor to overheat.

1.2 OBJECTIVE OF THE PROJECT

This is a starting method that reduces the starting current and starting torque of a motor. The objective of this work is to describe a star-delta electric motor panel for a 5hp motor.

1.3 SCOPE OF THE PROJECT

The Star Delta starting method is a motor starting mechanism that minimizes the large amount of starting current that motors draw in. The Star Delta, as the name suggests basically involves feeding the motor with 1/sq.root3 (58%) of the full load current until it attains speed then applying the full load current.
Traditionally, in many regions there was a requirement that all motor connections be fitted with a reduced voltage starter for motors greater than 4KW 5HP.This was to curb the high inrush of starting currents associated with starting induction motors.

1.4 SIGNIFICANCE OF THE PROJECT

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

1.5 LIMITATION OF THE PROJECT

Low Starting Torque (Torque = (Square of Voltage) is also reduce).
Break In Supply – Possible Transients
Six Terminal Motor Required (Delta Connected).
It requires 2 set of cables from starter to motor.
It provides only 33% starting torque and if the load connected to the subject motor requires higher starting torque at the time of starting than very heavy transients and stresses are produced while changing from star to delta connections, and because of these transients and stresses many electrical and mechanical break-down occurs.
In this method of starting initially motor is connected in star and then after change over the motor is connected in delta. The delta of motor is formed in starter and not on motor terminals.
High transmission and current peaks: When starting up pumps and fans for example, the load torque is low at the beginning of the start and increases with the square of the speed. When reaching approx. 80-85 % of the motor rated speed the load torque is equal to the motor torque and the acceleration ceases. To reach the rated speed, a switch over to delta position is necessary, and this will very often result in high transmission and current peaks. In some cases the current peak can reach a value that is even bigger than for a D.O.L start.
Applications with a load torque higher than 50 % of the motor rated torque will not be able to start using the start-delta starter.
Low Starting Torque: The star-delta (wye-delta) starting method controls whether the lead connections from the motor are configured in a star or delta electrical connection. The initial connection should be in the star pattern that results in a 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.
The transition from star to delta transition usually occurs once nominal speed is reached, but is sometimes performed as low as 50% of nominal speed which make transient Sparks.

1.6 FEATURES OF STAR-DELTA MOTOR

For low- to high-power three-phase motors.

Reduced starting current
Six connection cables
Reduced starting torque
Current peak on changeover from star to delta
Mechanical load on changeover from star to delta

1.7 APPLICATION OF STAR-DELTA MOTOR

The star-delta method is usually only applied to low to medium voltage and light starting Torque motors.

The received starting current is about 30 % of the starting current during direct on line start and the starting torque is reduced to about 25 % of the torque. This starting method only works when the application is light loaded during the start.

If the motor is too heavily loaded, there will not be enough torque to accelerate the motor up to speed before switching over to the delta position.

1.8 COMPONENTS OF STAR-DELTA MOTOR

Star-delta motor Consists following units

Contactors (Main, star and delta contactors) 3 No’s (For Open State Starter) or 4 No’s (Close Transient Starter).
Time relay (pull-in delayed) 1 No.
Three-pole thermal over-current release
Fuse elements or automatic cut-outs for the main circuit
Fuse element or automatic cut-out for the control circuit