Grundfos Motor Book Grundfos Motor Book

210  Grundfos Motor Book

10.  Starting methods

Starting methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Inrush current or locked-rotor current? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Direct-on-line starting (DOL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Drawbacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Star-delta starting (SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Drawbacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Comparison of direct-on-line starting and star-delta starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Auto-transformer starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Drawbacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Torque versus voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Soft starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Drawbacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Frequency converter starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Drawbacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Run-up time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Grundfos Motor Book  211

10. Starting methods Grundfos Motor Book

Starting methods

Starting methods
Today, various methods for starting motors are Rated motor current during acceleration
available. Changes, such as higher starting cur-
rents for new energy-efficient motor designs, Starting current
mean greater focus on starting methods. This is
closely linked to the fact that power quality has

% Full-load current

% Full-load current
become a much more important issue in recent
years, which has in turn led to greater emphasis on
voltage transients associated with the start-up of
large motors. This section will outline the various
starting methods used today and provide brief
descriptions of their advantages and drawbacks.
Full-load current

Inrush current or locked-rotor current?

When a motor is energized, the resulting initial
% Synchronous speed Time
current transient is known by various names:
inrush current, starting current, or locked-rotor
The surge current is reduced as the motor accelerates
current. Mostly, these terms all refer to the same
up to its full-load speed
thing: a very large current – five to ten times
the full-load current – flows initially. This surge
current drops as the motor accelerates up to its
running speed.

Different starting methods are used in order to

reduce the starting current to comply with local
laws and regulations. Naturally, avoiding huge
voltage drops on the mains is a significant objec-
tive in its own right.

On the following pages, you can read about the

most common starting methods: Direct-on-line
starting, star-delta starting, auto-transformer
starting, soft starting and frequency converter
starting.

212  Grundfos Motor Book

 10. Starting methods

Direct-on-line starting

Direct-on-line starting
As the name suggests, direct-on-line starting
means that the motor is started by connecting it
directly to the supply at rated voltage. Direct-on-
line starting, (DOL), is suitable for stable supplies
and mechanically stiff and well-dimensioned K1

shaft systems – and pumps qualify as examples

of such systems.
MV 1

Advantages
DOL starting is the simplest, cheapest and most
common starting method. Furthermore it actu-
ally gives the lowest temperature rise within
the motor during start up of all the starting
K 1 = Main contactor
methods. It is the obvious choice wherever the MV 1 = Overload relay
supply authority’s current limiting restrictions
allow for its use. Power plants may have varying
rules and regulations in different countries; for
example, three-phase motors with locked-rotor
% Full-load torque

currents above 60 A must not use direct-on-line Breakdown torque

starting in Denmark. In such cases, it will obvi-
ously be necessary to select another starting Starting torque
method. Motors that start and stop frequently
often have some kind of control system, which
consist of a contactor and overload protection Full-load torque
such as a thermal relay.

Drawbacks
Small motors which do not start and stop fre-
% Synchronous speed
quently need only very simple starting equip-
ment, often in the form of a hand-operated
motor protection circuit breaker.
600 Max starting current

Full voltage is switched directly onto the motor 500

% Full-load current

terminals. For small motors, the starting torque

will be 150% to 300% of the full-load value, 400

while the starting current will be 300% to 800% 300

of the full-load current or even higher.
200

Full-load current
100

% Synchronous speed

Grundfos Motor Book  213

10. Starting methods Grundfos Motor Book

Star-delta starting

Star-delta starting
The objective of this starting method, which is 6
, , ,

used with three-phase induction motors, is to

6
reduce the starting current. In starting position,
current supply to the stator windings is connected K3 K 2 K1 +
+
in star (Y) for starting. In the running position,
current supply is reconnected to the windings in -6
delta (∆) once the motor has gained speed.

Advantages +

Normally, low-voltage motors over 3 kW will be

-
dimensioned to run at either 400 V in delta (∆) 

connection or at 690 V in star (Y) connection. The

MV 1 Line diagram for star-delta starter
flexibility provided by this design can also be used Star-delta starter with
to start the motor with a lower voltage. Star-delta contactors and overload relay
K 1 = Main contactor
connections give a low starting current of only K 2 = Delta contactor
about one third of that found with direct-on-line K 3 = Star contactor
MV 1 = Overload relay
starting. Star-delta starters are particularly suited
for high inertias, where the load are initiated
after full load speed.

Change Y > D
Drawbacks
% Full-load torque

But they also reduce the starting torque to

about 33%. The motor is started in Y-connection
and accelerated and switched to the star-delta
connection. This method can only be used with
induction motors that are delta connected to the
supply voltage.

If the changeover from star to delta takes place

Pump load
at too low a speed, this can cause a current
surge which rises almost as high as the corre-
sponding DOL value. % Synchronous speed

During the even small period of switch over

from start to delta connection the motor looses 600
speed very rapidly, which also calls for higher
500
% Full-load current

current pulse after connection to delta. Change Y > ∆

400
The two illustrations to the right show two fea-
tures which should be taken into consideration 300

when using star-delta starting. The starter first

200
connects the motor in star (contactor K1 and
K3). After a time period – which depends on 100

individual needs – it connects the motor in delta 0

contactor K3 open and contactor K2 close.
% Synchronous speed

214  Grundfos Motor Book

 10. Starting methods

Star-delta starting

Grundfos pumps and motors which carry the

designation 3 x 380 - 415 V ∆ but NOT 690 V Y
can also be started by means of star-delta start-
ers, while the real voltage to the motor never oa
d
l

% Full-load torque
exceed 400 V. mp
Pu

Starting torque and current are considerably lower Moto

r
at star-delta starting than at direct-on-line start-
ing: one third of the equivalent DOL value.

Mismatching of motor torque speed curve and

load torque speed curve. In the example shown
here, the motor would slowly accelerate up to
approximately 50 per cent rated speed.
% Synchronous speed

Mismatching of motor torque speed curve and

the load torque speed curve. In this example, the
motor would slowly accelerate up to approxi-
mately 50 per cent rated speed.

Grundfos Motor Book  215

10. Starting methods Grundfos Motor Book
Comparision of DOL and
star-delta starting

Comparision of DOL and

star-delta starting
The following graphs illustrate currents for a
Grundfos CR pump started with a Grundfos MG
7.5 kW motor by means of DOL and star-delta
starting, respectively. As you will see, the DOL
starting method features a very high locked-rotor
current which eventually flattens and becomes
constant. The star-delta starting method features
a lower locked-rotor current, but peaks during the
starting process as the changeover from star to
delta is made.

When starting in star (t = 0.3 s), the current is

reduced. However, when switching over from
star to delta (at t = 1.7 s), the current pulse reaches
the same level as the locked-rotor current seen
with direct-on-line starting. The current pulse can
even get higher, because the motor during the Direct-on-line starting of a Grundfos 7.5 kW motor
switching period is un-powered which means it installed on a Grundfos CR pump
reduce speed before the full voltage (delta volt-
age) are supplied.

Star-delta starting of a 7.5 kW Grundfos motor

installed on a Grundfos CR pump

216  Grundfos Motor Book

 10. Starting methods

Auto-transformer starting

Auto-transformer starting
As the name clearly states, auto-transformer
starting makes use of an auto-transformer cou-
pled in series with the motor during starting.

Advantages
The auto-transformer contains transformers,
often featuring two voltage reductions, which
reduce voltage to provide low-voltage starting
by tapping off the secondary voltage of the
auto-transformer, usually at approximately 50
Auto-transformers and Reactors
- 80 per cent of full voltage. Only one tapping
is used, depending on the starting torque/cur-
rent required. Of course, reduced voltage to Curr
600 ent
the motor will result in reduced locked-rotor wit
hou
ta
uto
current and torque, but this method gives the 500 -tr
an
sfo
% Full-load current

highest possible motor torque per line ampere. Current in

rm
er
400 2nd st (D
OL
At no point in time is the motor not energised, ep
)
so it will not loose speed as is the case with star- 300
Current in 1st
step
delta starting. The time of the switch between
200
reduced and full voltage can be adjusted to suit
specific requirements. 100

0
Drawbacks
Besides a reduced locked rotor torque, the % Synchronous speed
autotransformer starting method has yet anoth-
er disadvantage.
Once the motor has started running, it is switched
over to the mains voltage – this will cause a cur-
rent pulse.
% Full-load torque

Torque versus voltage

The values for starting torque are reduced at a
rate corresponding to the square of the reduction Full
voltag
in volts. e torque

Torq
ue in 2 step
nd
Tor
que
on 1st step

( )
2 Pump load
Voltage2 Torque2
=
Voltage1 Torque1
% Synchronous speed

( )
U2 2 T2
U1
=
T1

Grundfos Motor Book  217

10. Starting methods Grundfos Motor Book

Soft starting

Soft starting
A soft starter is, as you would expect, a device
which ensures a soft start of a motor.

Advantages
Soft starters are based on semiconductors. Via
a power circuit and a control circuit, these semi-
conductors reduce the initial motor voltage. This
results in lower motor torque. During the starting
process, the soft starter gradually increases the
motor voltage, thereby allowing the motor to
accelerate the load to rated speed without causing
high torque or current peaks.
Soft starters can also be used to control how pro-
cesses are stopped. Soft starters are less expensive
than frequency converters.
Softstarter
Drawbacks
They do, however, share the same problem as
frequency converters: they may inject harmonic
currents into the system, and this can disrupt
other processes.

The starting method also supplies a reduced

voltage to the motor during start-up. The soft
starter starts up the motor at reduced voltage,
and the voltage is then ramped up to its full Voltage ramp for soft starter.
value. The voltage is reduced in the soft starter Run-up time is around 1 sec.
via phase angle. In connection with this starting
method current pulses will not occur. Run-up
time and locked-rotor current (starting current)
can be set. 600
% Full-load current

500
% Full-load torque

400

300

200

100

Pump load 0

% Synchronous speed % Synchronous speed

218  Grundfos Motor Book

 10. Starting methods

Frequency converter starting

Frequency converter starting

Frequency converters are designed for continuous
feeding of motors, but they can also be used for
start-up only.

Advantages
The frequency converter makes it possible to use
Frequency
low starting current because the motor can pro-
converter
duce rated torque at rated current from zero to
full speed. Frequency converters are becoming
cheaper all the time. As a result, they are increas-
ingly being used in applications where soft starters
would previously have been used.

Drawbacks Frequency converter

Even so, frequency converters are still more
expensive than soft starters in most cases; and Line diagram for a motor
like soft starters, they also inject harmonic cur- operated by a frequency
rents into the network. converter
% Full-load torque

% Synchronous speed

600

500
% Full-load current

400

300

200

100

% Synchronous speed

Grundfos Motor Book  219

10. Starting methods Grundfos Motor Book
Run-up times
Summary

Run-up times
As regards those starting methods which are
to reduce the locked-rotor current, the run-up
time must not be too long. Excessive run-up
times will cause unnecessary heating of the
winding.

Summary
The principle objective of all methods of motor
starting is to match the torque characteristics
to those of the mechanical load, while ensur-
ing that the peak current requirements do not
exceed the capacity of the supply. Many start-
ing methods are available, each of which has
slightly different characteristics. The following
table
summarizes the main characteristics for the
most popular starting methods.

Starting method Pros Cons

Direct-on-line starting Simple and cost-efficient. Safe starting. Highest High locked-rotor current.
(DOL) possible starting torque

Star/delta starting Reduction of locked-rotor current by a factor 3. High current pulses when switching over
(SD) from star to delta.
Not suitable if the load has a low inertia.
Reduced locked-rotor torque.
Auto-transformer Reduction of locked-rotor current by u2, where u is Current pulses when switching from
the voltage reduction e.g. 60% = 0.60. reduced to full voltage.
Reduced locked-rotor torque.
Soft starter “Soft” starting. No current pulses. Reduced locked-rotor torque.
Less water hammer when starting a pump.
Reduction of locked-rotor current as required,
typically 2-3 times.
Frequency starter No current pulses. Reduced locked-rotor torque.
Less water hammer when starting a pump. Expensive.
Reduction of locked-rotor current as required,
typically to around full-load current. Can be used
for continuous feeding of the motor.

220  Grundfos Motor Book

10. Starting methods

Summary

Grundfos Motor Book  221