Documentos de Académico
Documentos de Profesional
Documentos de Cultura
Rev 5058-CO900B
RAOTM - Topic
Title:
Practical applications of Soft Starter technology for improved performance
and energy management
Description:
Increase your technical competency and understanding of the latest Soft
Starter technology, and find out how SMC's can be applied to maximize your
investment and energy efficiency. This session will include a brief overview
on technology, recent advancements, application examples and
considerations, use of the SMC Application Wizards, and an overview of the
Allen Bradley SMC portfolio.
Agenda
UnderstandSoft
SoftStarter
StarterTechnology
Technology
Understand
RecentAdvancements
Advancements
Recent
ApplicationExamples
Examplesand
andConsiderations
Considerations
Application
ApplicationWizards
Wizards
Application
AllenBradley
BradleySMC
SMCPortfolio
Portfolio
Allen
Basic
Advanced
Copyright 2012 Rockwell Automation, Inc. All rights reserved.4
Todays RVS
Auto Transformer
Part Winding
Wye-Delta (Star-Delta)
Primary Resistance
Primary Inductance
Wound Rotor
SCRs fire
Gate
SCR
SCR Control
A. Using SCRs in an opposed (back to back) configuration, the full sine wave of the
B.
Gate Signal
Gate
SCR
VOUT
VIN
B
Copyright 2012 Rockwell Automation, Inc. All rights reserved.6
Full Voltage
Starting Characteristics
Starting Current
~6xFLA
Break-down
torque
Pull-up torque
180%
Full load
torque
100%
Speed -%RPM
100%
180%
Percentage
of Full Rated
Torque
100%
100%
Copyright 2012 Rockwell Automation, Inc. All rights reserved.
100
%
72%
300%
%FLA
510%
100% Voltage
(amps)
600%
85% Voltage
(ftlb)
Torque
Example
Full Load
50% Voltage
25%
0
Current
Torque
Speed -RPM
100
%
Torque required
by the load
Agenda
UnderstandSoft
SoftStarter
StarterTechnology
Technology
Understand
RecentAdvancements
Advancements
Recent
ApplicationExamples
Examplesand
andConsiderations
Considerations
Application
ApplicationWizards
Wizards
Application
AllenBradley
BradleySMC
SMCPortfolio
Portfolio
Allen
Solid State insures minimal amount of energy to accelerate motor even if the load only
requires 25% torque.
Inherent Diagnostics
2 Phase
3 Phase
Increased Heating
Increased Vibration during Starting
iv l
c/Dc tota
e
2 S 3 Se
=
Time
Parameter Settings: = Start Time: 10 second
Copyright 2012 Rockwell Automation, Inc. All rights reserved.16
Time
Parameter Settings: =Start Time: 10 second
Copyright 2012 Rockwell Automation, Inc. All rights reserved.17
Energy Savings
Reduce the total amount of energy consumed
Scalable Performance
SMC Flex and SMC-50 Provide advanced Power and Energy Monitoring
Measurement it = manage it
Visibility = helps provide business case support for future process and product improvements
Agenda
UnderstandSoft
SoftStarter
StarterTechnology
Technology
Understand
RecentAdvancements
Advancements
Recent
ApplicationExamples
Examplesand
andConsiderations
Considerations
Application
ApplicationWizards
Wizards
Application
AllenBradley
BradleySMC
SMCPortfolio
Portfolio
Allen
VFD/Drive
Limited Functionality
Unless used with
advanced Overload
180%
100%
Percentage
of Full Load
Torque
0
100%
Percentage of Full Speed
SMC:
Lengthens system life by reducing mechanical stress during starting Reduces DOWN Time
Helps reduce/eliminate PMO on equipment
No need to replace damaged parts
Minimal production loss
Copyright 2012 Rockwell Automation, Inc. All rights reserved.23
600%
Percentage
of Full Load
Current
100%
0
100%
Percentage of Full Speed
Mechanical?
Power Limitations?
Simplicity?
Soft Start
Soft Stop
Current Limit
Soft Start/CL with Kick Start
Pump Control
Torque Control
Linear Acceleration/Deceleration
Special Modes
Dual Ramp
Full Voltage
Slow Speed
Custom Starting Profiles
Smart Motor Braking
Combination of profiles
Soft Start
Full Voltage
Torque Control
Similar to Pump Control performance but applicable for all load types
More difficult to apply but yields higher level of performance
Linear Acceleration/Deceleration
Simplest starting, lowest current , most consistent starting time per start regardless of load
Torque
Full
Load
Soft Start
Pump Start
Pump System
Speed
Full Speed
True, moans and groans of all kinds can be heard in a motor during braking
True, the SMC produces some harmonic distortion during starting and stopping, however the
levels are insignificant (typically < 10% of the fundamental)
False, SMB is not intended to be used for E-Stop scenarios. To many variables are involved
which can alter the performance of this feature
False, Braking is hard, but we can not create more energy then what the motor demands.
Motor damage is typically caused by incorrect settings or normal wear and tear
SMC
Special Application Considerations
Multi-Motor Applications
SMC
Special Application Considerations
Power Source Sizing Guidelines
Ideally, the source would be sized for a full voltage start. (Somewhat impractical today)
When sizing for use with a generator it is critical that the generator is able to stay in proper
regulation under starting or braking loads.
Rule of thumb: Avoid sizing the supply for anything less the 300% of the motors FLA.
SCR Fusing for SCR Protection (Very Fast Acting Semiconductor type fuse)
Use is not suggested in High Inertia, Braking, or Pump stop applications (Applications with
Start times > 30 seconds) due to potential for nuisance tripping
Can be used to achieve Type 2 Coordination in some cases
See SMC Wizard Short Circuit Protection (SCPD) Wizard for further guidance
SMC
Special Application Considerations
Power Factor Correction Capacitors
Line side only - locating load side can damage the SCR
Ideally PFCC are brought in with up-to-speed contact
Dynamic Correction can be responsible for nuisance line faults
For best operation try to size SMC-3 mid range per Selection Guide/Catalog
Simply choose based on voltage, horsepower, current and insure that the motor FLA
fits the SMCs operating range
Flywheel, chippers, grinders, braking, retrofits, running vs. starting req. etc.
Thermal Analysis may be required to determine proper size for the following:
Agenda
UnderstandSoft
SoftStarter
StarterTechnology
Technology
Understand
RecentAdvancements
Advancements
Recent
ApplicationExamples
Examplesand
andConsiderations
Considerations
Application
ApplicationWizards
Wizards
Application
AllenBradley
BradleySMC
SMCPortfolio
Portfolio
Allen
Application Wizard
Agenda
UnderstandSoft
SoftStarter
StarterTechnology
Technology
Understand
RecentAdvancements
Advancements
Recent
ApplicationExamples
Examplesand
andConsiderations
Considerations
Application
ApplicationWizards
Wizards
Application
AllenBradley
BradleySMC
SMCPortfolio
Portfolio
Allen
Performance / Functionality
SMC-50
SMC Flex
SMC Dialog
SMC-3
SSC
5
25
100
200
500
800
1000
1600
Allen-Bradley
SMC Contemporary Offering
SMC-3
Hybrid Power Structure
SMC Flex
Hybrid Power Structure
SMC-50
Solid State Power Structure
Copyright 2012 Rockwell Automation, Inc. All rights reserved.43
SMC Family
Choosing a Power Platform
True Solid State
AC53-B
Smaller
Total Footprint
Less
External Wiring
Optimized Thermal
Management
Easy Product
Selection
Lower Total
Installed Cost
AC53-A
Higher SCCR
ratings
Phase
Rebalance/Energy
Saver Capability
Higher
operations/hour
Scalable Thermal
Ratings
Copyright 2012 Rockwell Automation, Inc. All rights reserved.
SMC Family
Choosing a Power Platform
Internal Bypass (SMC-3, SMC Flex)
SMC Family
Choosing the control for your application
Which control modes are required?
SMC-50, Flex & SMC-3
SMC-50, SMC-Flex
Soft Start
Soft Stop
Current Limit
Soft with Kick Start
Pump Control
Slow Speed
Dual Ramp
Full Voltage Starting
Smart Motor Braking
Linear Accel/Decel (SMC-50 Only)
Torque Control (SMC-50 Only)
The SMC Flex / 50 also offer power metering features as well as communication options
enhancing configuration, control and data collection capabilities!
Copyright 2012 Rockwell Automation, Inc. All rights reserved.46
SMC-3 Overview
Compact Series
4 Starting/Stopping Modes
Basic Diagnostics
Compact design provides 3 phase control, increased intelligence, and unmatched
performance. Motor and system diagnostics and an electronics overload with adjustable
trip class help reduce downtime and protect assets.
SMC-3 Overview
Line Ratings
Frame 1 (3 A, 9 A,16 A, 19 A, 25 A, 30 A, 37 A)
Frame 2 (43 A, 60 A, 85 A)
Frame 3 (108 A, 135 A)
Frame 4 (201 A, 251 A)
Frame 5 (317 A, 361 A, 480 A)
Delta Ratings
3 831 amps
Two line voltage ratings
200480V or 200600V @ 50/60 Hertz
Two control voltage
24V AC/DC or 100240V AC
050C Operating temperature
9 Start/Stopping Modes
3 slow-speed modes
Smart Motor Braking
Line Ratings
5.1250 Amps
Delta Ratings
81600 Amps
0 - 50 C Operating Temperature
Starting Modes
Soft-Start
Soft-Stop
Current Limit Start
Full Voltage
Preset Slow Speed
Linear Speed Acceleration
Dual Ramp
Pump Control (optional)
15 Start/Stopping Modes
3 slow-speed modes
Smart Motor Braking
Full power and energy management, Real Time Clock, Event Log
Designed for customer flexibility 3 phase control and scalable options help
maximize the total motor control investment. Advanced monitoring and protection,
superior communication capabilities and energy saver modes help increase
operating efficiencies and reduce downtime.
100 Ka Fuses
65 Ka Breaker
Thank You!
Find More Information on SMC Products
Visit us @ WWW.AB.com
Back-Up Slides
Soft Start
Current Limit w/ Kick Start
Pump Control
EW!
N
Enhanced Slow Speed: 1% to 15%
!
NEW
Patented Sensor-less Linear Acceleration*
Consistent ramp up time (no tachometer
required)
Optimizes energy consumption
Coast
Soft Stop
Smart Motor Braking (SMB)
Linear Deceleration NEW!
External Braking Control NEW!
Pump Control
Motor Winding Heater NEW!
Energy Saver
Emergency Run
*SMC Flex provides Linear Acceleration Start, however it requires a tachometer for speed feedback
Copyright 2012 Rockwell Automation, Inc. All rights reserved.55
Simplest to Setup
2 Parameters Required to configure: Ramp Time and Initial Torque (used as reference)
Reduces/eliminates the need for the Dual Ramp mode
Always uses the minimum amount of energy needed to accelerate the motor in the time requested
(regardless of the loading condition)
Torque Control algorithms are useful for basic applications (pumps, compressors)
Basic Setup Parameters:
Ramp Time, Starting Torque, Max Torque(M), Rated Torque(M) and Rated Speed Settings(M)
2 Sec/Div
= 10 Sec total
2 Sec/Div
= 5 Sec total
Higher Peak Current
Time
NOTEs:
- Actual Start time difference of Linear versus torque mode
- Smoother torque curve for Linear versus torque mode
- Lower peak current with Linear Acceleration mode
Slow Speed, Motor Winding Heater, Energy Saver, Phase Rebalance, DeviceLogix