27 Application Guide for Reduced Voltage Autotransformer Starter Application Guide for Reduced Voltage Autotransformer Starter 28

Background: Contactor Switching Sequence

With the introduction of M-Line range of controlgear products and F-Line range of SDFs a need for a Contactor Start Transition (initial) Transition (final) ON
comprehensive selection chart for autotransformer motor feeder was felt necessary. Also, we have been KM1 (Star) Close Open Open Open
receiving queries from various branches for an application guide on the same.
KM2 (Step) Close Close Close Open
Brief Description: KM3 (Main) Open Open Open Close

An autotransformer starter reduces inrush current by using a transformer in the line just ahead of the motor When the motor is directly switched to lines, the motor current is generally 6 times the full load current.
to step down the voltage applied to the motor terminals. By reducing the voltage, the current drawn from the
line is reduced during start-up. Istart = 6I n = V/Z (3) 1/3
Ø

Starting with reduced voltage decreases the full load current at the motor terminals in proportion to the Istart = Starting motor current
voltage reduction while the full load torque is reduced by the square of the voltage reduction. In = Full load current
V = Line voltage
Recommended Wiring Diagram
In case of autotransformer if a tapping of transformation ratio K is used, then Vph across motor is KV/(3) 1/3
1/l1

3/l2

5/l3

-Q1
Motor Current during start; I = KV/Z (3) 1/3
12

34

56

-F2 = KIstart
2

= K*6In
1

5
1

-KM3 -KM2
W1 6
U1 2

V1 4
2

The current taken by the autotransformer is KI2.

-T1 = K2 *6In
U3
V3
= K 2 Istart
W3
6 W2
W
U

2 U2
V

4 V2

M -KM1 Hence, though the motor current is reduced by only K times the direct switching current, the current taken by
3~ the line is reduced by K2 times.
1

Operation Similarly for starting torque,

In autotransformer starters, the motor is started at reduced voltage, which is supplied from an
autotransformer. The starting sequence has three stages. T1 ∞ (V/31/3)2
Ø
T1 = torque during direct starting.
During the first stage, the autotransformer is star connected, and the line contactor is closed. This starts the
motor with a reduced voltage, the value of which depends upon the ratio selected for the transformer.
Autotransformers are normally provided with taps to allow the best ratio to be chosen during commissioning. With an autotransformer,

In the second stage, the star connection is opened, and the autotransformer acts as an inductor connected T2 ∞ (kV/31/3)2
Ø
in series with the motor. This transition is normally timed to occur when the motor speed has stabilized at the
T1 = torque with autotransformer starting.
end of the run-up period.

The third stage then follows almost immediately, and involves shunting the transformer completely, so that Hence, T2 / T1 = K2
the motor is directly connected to the supply.
Starting torque with autotransformer = K2 * Starting torque with direct on-line
starting.
As shown in the wiring diagram
Ø Star connection of the autotransformer is made by KM1, then contactor KM2 closes and the motor starts
under reduced voltage.
Thus it provides maximum starting torque with minimal line current. Due to transformer action, the line
current will be 25 %, 42 % or 64 % of full voltage values for the 50 %, 65 % or 80 % taps respectively.
Ø
The neutral point is opened by KM1; part of the autotransformer winding is switched into each phase for a
short moment, constituting a stator starting inductance.

Ø
KM3 switches the motor to full mains voltage and causes the autotransformer to be shunted out of circuit
by KM2.

Technical Articles
29 Application Guide for Reduced Voltage Autotransformer Starter Application Guide for Reduced Voltage Autotransformer Starter 30
Operating Curves Mtor Ratg: 3Ø, 415, 50 Hz Contactor Relay

HP kW In (A) MaIn (KM3) Step (KM2) Star (KM1) Type Range (A) Fuse Rating (A) SDF
Currant

XIN XCN

Torqua
7 2.5
50% 65% 80%
I 6
D 7.5 5.5 11.2 MO 12 MO 9 MO 9 MO 9 MO 9 RTO - 1 8.5-12.5 HF 32 FN 32
2
5 10 7.5 14.8 MO 18 MO 9 MO 9 MO 12 MO 9 RTO - 1 12.5-18.5 HF 32 FN 32
1 1.5
4 12.5 9.3 19 MO 25 MO 9 MO 9 MO 18 MO 9 RTO - 1 17-25.5 HF 50 FN 63
1
I 3 C 1 15 11 22 MO 25 MO 9 MO 12 MO 18 MO 12 RTO - 1 17-25.5 HF 63 FN 63
2 N
2 2
17.5 13 24 MO 32 MO 9 MO 12 MO 18 MO 12 RTO - 1 17-25.5 HF 63 FN 63
2
0.5
3 20 15 29 MO 32 MO 9 MO 18 MO 25 MO 18 RTO - 1 25-37 HF 63 FN 63
I 1
N
0 25 18.6 35 MO 40 MO 9 MO 18 MO 25 MO 18 RTO - 1 25-37 HN, 000 80 FN 100
0 0 0.25 0.50 0.75 1
0 0.25 0.50 0.75 1 Speed 30 22.5 40 MO 45 MO 12 MO 18 MO 32 MO 18 RTO - 1 35-45 HN, 000 80 FN 100
Speed
35 26 47 MO 50 MO 12 MO 25 MO 32 MO 25 RTO - 2 40-57 HN, 000 100 FN 100

1. Direct Switching Current 1. Direct Motor Torque 40 30 55 MO 70 MO 18 MO 25 MO 40 MO 25 RTO - 2 40-57 HN, 000 100 FN 100

2. Current with Autotransformer 2. Torque with Autotransformer 45 33.5 60 MO 70 MO 18 MO 32 MO 40 MO 32 RTO - 2 50-75 HN, 000 100 FN 100
3. Load Torque 50 37 66 MO 80 MO 18 MO 32 MO 45 MO 32 RTO - 2 50-75 HN, 00 125 FN 125

60 45 80 MO 95 MO 25 MO 40 MO 70 MO 40 RTO - 3 75-110 HN, 00 125 FN 125

75 55 100 MO 110 MO 32 MO 45 MO 70 MO 45 RTO - 3 75-110 HN, 00 160 FN 160

The autotransformer motor starter selection chart is based on the closed transition which never disconnects the
motor from the power source, and transient phenomena are eliminated. This is also known as ‘Korndorfer’ 90 67.5 120 MO 140 MO 32 MO 70 MO 80 MO 70 RTO - 4 105-156 HN, 0 200 FN 200
method. 100 75 135 MO 140 MO 40 MO 70 MO 95 MO 70 RTO - 4 105-156 HN, 0 200 FN 200

110 80 139 MO 185 MO 40 MO 70 MO 95 MO 70 RTO - 4 138-201 HN, 0 200 FN 200

The transition from reduced voltage to full voltage on motor starters can be based on current or time. The over
current relay monitors the motor current. When the motor current drops below the preset value, the relay signals 125 90 165 MO 185 MO 45 MO 95 MO 110 MO 95 RTO - 4 138-201 HN, 1 250 FN 250
the motor starter to switch to full voltage. Or when the setting time on the timer has expired, the autotransformer is
150 110 200 MO 225 MO 70 MO 95 MO 140 MO 95 RTO - 4 138-201 HN, 1 250 FN 250
bypassed.
175 130 230 MO 250 MO 70 MO 110 MO 185 MO 110 RTO - 4 201-291 HN, 1 315 FN 315
Typically autotransformer has three taps, which provide 50%, 65% and 80% of full line voltage. The 197 147 260 MO 300 MO 70 MO 140 MO 185 MO 140 RTO - 4 201-291 HN, 2 400 FN 400
autotransformer starter can be used for any squirrel-cage motor. Typically autotransformer has three taps,
which provide 50%, 65% and 80% of full line voltage. The autotransformer starter can be used for any squirrel- 200 150 275 MO 300 MO 70 MO 140 MO 185 MO 140 RTO - 4 201-291 HN, 2 400 FN 400

cage motor. 215 160 280 MO 300 MO 80 MO 140 MO 185 MO 140 RTO - 4 201-291 HN, 2 400 FN 400

225 168 300 MO 300 MO 80 MO 140 MO 225 MO 140 RTO - 4 255-375 HN, 2 400 FN 400
Conclusion:
This chart provides aready reckoner for selection of components for an autotransformer motor feeder. 245 180 320 MNX 400 MO 95 MO 140 MO 225 MO 140 RTO - 4 255-375 HN, 2 400 FN 400

270 200 340 MNX 400 MO 95 MO 185 MO 225 MO 185 RTO - 4 255-375 HN, 3 500 FN 630

300 225 385 MNX 550 MO 110 MO 185 MO 250 MO 185 MN 12 340-570 HN, 3 500 FN 630

335 250 425 MNX 550 MO 110 MO 185 MO 300 MO 185 MN 12 340-570 HN, 3 500 FN 630

400 300 500 MNX 550 MO 140 MO 225 MO 300 MO 225 MN 12 340-570 HN, 3 630 FN 630

430 315 535 MNX 550 MO 140 MO 300 MNX 400 MO 250 MN 12 340-570 HN, 3 630 FN 630

Technical Articles
31 Length of control cables Length of control cables 32
Introduction The following table gives a ready reckoner of maximum control cable length for MX contactor (AC) to ensure
a clear drop off when control supply is cut off:
There is an inherent capacitance in cables. The cable capacitance indicates how much charge the cable can
store within itself. If a voltage is being applied the insulation on the individual wires becomes charged by the
Hold-On Min Drop-off
voltage. This cable capacitance is defined in µF/km. With higher lengths of cable the ability to store charge also Voltage/Rated voltage L (m) <
Family Contactors Power PH
increases. (VA)
Ud / Uc 110 V 240 V 415 V
With advent of technology and focus on energy saving, contactors are also becoming energy efficient and MX mini MX 0/6/9/12 AC 4.5 0.3 1365.74 286.63 95.95
compact. However there is one issue linked with low VA consumption of AC coil of contactors. When the control
MNX 9 - 40 11 0.35 3751.0 788.0 263.5
cable length is high, the cable capacitance is more and it may be sufficient to store energy for providing hold on
VA to contactor coil. This may lead to delayed drop off of the contactor. This applies to contactors operating with MNX 50 - 80 21 0.35 7161.0 1504.3 503.1
AC control supply only. MNX 95 - 140 36 0.35 12276.0 2578.8 862.5
MNX
The effect of cable capacitance depends on the design of the control circuit as shown below, MNX 185 - 225 56 0.35 19096.1 4011.5 1341.6
L1 MNX 300 - 400 95 0.35 32395.1 6805.2 2276.0
N
MNX 550 - 650 25 0.35 8525.0 1790.8 598.9
MO 9 - 45 9 0.35 3069.0 644.7 215.6
CL Q11

MO MO 50 - 70 15 0.35 5115.0 1074.5 359.4

I

MO 80 - 110 25 0.35 8525.0 1790.8 598.9

In this case, when the coil is de-energized the net cable capacitance is disconnected from the supply and MO 140 - 225 50 0.35 17050.0 3581.7 1197.9
discharges through the coil. Hence there may be a slight delay in contactor drop off due to CL
MO 140 - 225 * 17 0.25 4472.0 939.4 314.2
L1
N MO 250 - 300 65 0.35 22165.0 4656.2 1557.2
CL
MO 250 - 300 * 17 0.25 4472.0 939.4 314.2
Q11
MO0 MO0 AC 9 0.4 1365.74 710.42 237.6
I
* Electronic coil version

In this case, the net cable capacitance continues to remain connected to the supply even after the coil supply is The following graphs give the trend of permissible control cable lengths with Hold-On VA at different voltage
switched off. This capacitance will feed the coil and if the energy stored in the capacitance is more than coil Hold- ranges. It must be noted that the trends are given at most common values of cable capacitances Cc.
on VA, the coil will continue to remain energized and the contactor will fail to drop. Cc= 0.2 and Cc = 0.3 μf/km

The problem of cable capacitances is mainly encountered in large scale installations such a crane systems in Applicable for MNX / MO Contactors
container terminals or where control is from field devices or automation system situated away from the control
panels. Cc = 0.2 µf / km For Cc = 0.3 µf / km
1000000 100000
Maximum permissible control cable length for reliable contactor drop off can be defined as below:

) ( PH ) meter
6
m * 10
L < 3.18 ( m+1 C *U 2
100000
10000
C C

where, 10000

L - Length of control cable in meter 1000

Length (m)

Length (m)
m - ratio of minimum drop-off voltage to rated coil voltage
1000
PH - Rated Hold-On power of the contactor in VA
CC - Cable capacitance per unit length in μF/km 100
UC - Rated control supply voltage in V 100

10
10

1 1
1 10 100 1000 1 10 100 1000

Hold On VA Hold On VA
110 V 240 V 415 V 110 V 240 V 415 V

Technical Articles