# Manufacturing Industry

In the manufacturing industry the following machines are usually operated, for which we can configure our starters:

## Turbo compressors

The moment of inertia of a turbo compressor normally ranges between 2 to 6 times the moment of inertia of the driving motor. Most of the compressor drives start with a starting time between app. 20 to 50 seconds. The torque speed curves (counter torque) of nearly all turbo compressors have a quadratic shape. They can be started with reduced load by regulating vanes and/or blades. By this a lower counter torque is reached which can further reduce the start current. Normal start currents for turbo compressors (I_{a}/I_{n}) are in the range of app. 1,5 - 2,5 times the motor rated current (I_{n}). Below you will find a characteristic example for a calculation. When starting a turbo compressor one has to observe that the critical speed will be run through fast enough to avoid mechanical vibration problems.

motor rated power | P_{n} |
2.000 | kW | ||||

rated voltage | U_{n} |
6.000 | V | ||||

motor rated current | I_{n} |
250 | A | ||||

motor start current DOL | I_{a} |
5 | × I_{n} |
||||

motor rated speed (synchronous) | n_{n} |
1.500 | rpm | ||||

moments of inertia | |||||||

motor | J_{M} |
80 | kgm^{2} |
||||

compressor | J_{L} |
300 | kgm^{2} |
||||

start voltage | U_{s} |
0,57 | × U_{n} |
||||

start time | t_{s} |
30 | s |

Torque

The starter starts the motor with reduced voltage, 57 % of the rated voltage, in this example (U_{s}/U_{n} = 0,57). The torque speed curve of the motor will be reduced by the factor T_{s}/T_{DOL} = (U_{s}/U_{n} × F)^{2}.

T_{s}/T_{DOL} = (0,57 × 0,91)^{2} = 0,27 (F is a factor depending on the motor). The torque of the motor must always be higher than the counter torque. The start voltage U_{s}/U_{n} has been determined accordingly. The difference between the reduced motor torque T_{s} and the counter torque is the acceleration torque T_{a}.

## Start time

The start time t_{s} is calculated from the acceleration torque T_{a} and the total moment of inertia J = J_{M} + J_{L} = 80 + 300 kgm^{2} = 380 kgm^{2}.

## Current

The motor current is I_{Mot} = U_{s}/U_{n} × I_{DOL} × F = 0,57 × 5 × 0,91 = 2,6 × I_{n}

**Mains start current:**

A transformer has the same power at primary and secondary, which leads to the fact that the products of current and voltage are the same.

U_{n} × I_{s} = U_{s}/U_{n} × I_{mot} => I_{s} = U_{s}/U_{n} × I_{Mot} / U_{n}

I_{s}= 0,57 × 2,6 = 1,5 × I_{n}

The mains start current is therefore much lower than the motor start current.

For other start methods (electronic soft starter, starting reactor etc.) the following is valid: The mains current equals the motor current:

I_{s} = I_{Mot} = 2,6 × I_{n}

For that reason these starting methods create a higher mains voltage drop.

## Screw compressors

Amongst others screw compressors are applied as refrigeration compressors for air condition (chiller). The moment of inertia of a screw compressor is significantly lower that the moment of inertia of the driving motor. Most of the screw compressors will start with start times between app. 10 to 20 seconds. They can be started with reduced load. This results in a lower counter torque which can further reduce the start current. Normal start currents for screw compressors (I_{a}/I_{n}) range from app. 1 -3 times the motor rated current (I_{n}). Below you will find a characteristic example for a calculation.

motor rated power | P_{n} |
2.000 | kW | ||||

rated voltage | U_{n} |
6.000 | V | ||||

motor rated current | I_{n} |
250 | A | ||||

motor start current DOL | I_{a} |
5 | × I_{n} |
||||

motor rated speed (synchronous) | n_{n} |
3.000 | rpm | ||||

moments of inertia | |||||||

motor | J_{M} |
45 | kgm^{2} |
||||

compressor | J_{L} |
8 | kgm^{2} |
||||

start voltage | U_{s} |
0,63 | × U_{n} |
||||

start time | t_{s} |
17 | s |

Torque

The starter starts the motor with reduced voltage, 63 % of the rated voltage, in this example (U_{s}/U_{n} = 0,63). The torque speed curve of the motor will be reduced by the factor T_{s}/T_{DOL} = (U_{s}/U_{n} × F)^{2}.

T_{s}/T_{DOL} = (0,63 × 0,91)^{2} = 0,33 (F is a factor depending on the motor). The torque of the motor must always be higher than the counter torque. The start voltage U_{s}/U_{n} has been determined accordingly. The difference between the reduced motor torque T_{s} and the counter torque is the acceleration torque T_{a}.

## Start time

The start time t_{s} is calculated from the acceleration torque T_{a} and the total moment of inertia J = J_{M} + J_{L} = 45 + 8 kgm^{2} = 53 kgm^{2}.

## Current

The motor current is I_{Mot} = U_{s}/U_{n} × I_{DOL} × F = 0,63 × 5 × 0,91 = 2,9 × I_{n}

**Mains start current:**

A transformer has the same power at primary and secondary, which leads to the fact that the products of current and voltage are the same.

U_{n} × I_{s} = U_{s}/U_{n} × I_{mot} => I_{s} = U_{s}/U_{n} × I_{Mot} / U_{n}

I_{s}= 0,63 × 2,9 = 1,8 × I_{n}

The mains start current is therefore much lower than the motor start current.

For other start methods (electronic soft starter, starting reactor etc.) the following is valid: The mains current equals the motor current:

I_{s} = I_{Mot} = 2,9 × I_{n}

For that reason these starting methods create a higher mains voltage drop.

## Piston compressors

Normally piston compressors do not have an especially high moment of inertia with reference to the motor speed. It is usually located in the range of app. 10 - 40% of the moment of inertia of the driving motor. Therefore, piston compressor drives can be started with a relatively short start time of app. 5-15 seconds. Piston compressors can be started nearly without load by pressure release. This is achieved by opening valves and results in a very low counter torque which greatly reduces the start current of the piston compressor. Start currents (I_{a}/I_{n}) during the start of piston compressors are ususally in the range of app. 1 - 2 times of the motor rated current (I_{n}). Below you will find a characteristic example for a calculation.

motor rated power | P_{n} |
2.000 | kW | ||||

rated voltage | U_{n} |
6.000 | V | ||||

motor rated current | I_{n} |
250 | A | ||||

motor start current DOL | I_{a} |
5 | x I_{n} |
||||

motor rated speed (synchronous) | n_{n} |
1.000 | rpm | ||||

moments of inertia | |||||||

motor | J_{M} |
150 | kgm^{2} |
||||

piston compressor | J_{L} |
35 | kgm^{2} |
||||

start voltage | U_{s} |
0,47 | x U_{n} |
||||

start time | t_{s} |
9 | s |

Torque

The starter starts the motor with reduced voltage, 47 % of the rated voltage, in this example (U_{s}/U_{n} = 0,47). The torque speed curve of the motor will be reduced by the factor T_{s}/T_{DOL} = (U_{s}/U_{n} × F)^{2}.

T_{s}/T_{DOL} = (0,47 × 0,9)^{2} = 0,18 (F is a factor depending on the motor). The torque of the motor must always be higher than the counter torque. The start voltage U_{s}/U_{n} has been determined accordingly. The difference between the reduced motor torque T_{s} and the counter torque is the acceleration torque T_{a}.

## Start time

The start time t_{s} is calculated from the acceleration torque T_{a} and the total moment of inertia J = J_{M} + J_{L} = 150 + 35 kgm^{2} = 185 kgm^{2}.

## Current

The motor current is I_{Mot} = U_{s}/U_{n} × I_{DOL} × F = 0,47 × 5 × 0,9 = 2,1 × I_{n}

**Mains start current:**

A transformer has the same power at primary and secondary, which leads to the fact that the products of current and voltage are the same.

U_{n} × I_{s} = U_{s}/U_{n} × I_{mot} => I_{s} = U_{s}/U_{n} × I_{Mot} / U_{n}

I_{s}= 0,47 × 2,1 = 1 × I_{n}

The mains start current is therefore much lower than the motor start current.

For other start methods (electronic soft starter, starting reactor etc.) the following is valid: The mains current equals the motor current:

I_{s} = I_{Mot} = 2,1 × I_{n}

For that reason these starting methods create a higher mains voltage drop.

## Other compressors

Compressors exist in a variety of different designs and types. For the most common ones (turbo, screw and piston) we have prepared detailled information for the start procedure. Needless to say, our starter can also be used for further compressor types. We will gladly provide you with an offer and technical support.

## Centrifugal pumps

Normally centrifugal pumps do not have an especially high moment of inertia. It is usually located in the range of app. 20-50% of the moment of inertia of the driving electric motor. Therefore, pump drives can be started with a relatively short start time of 5-15 seconds. The torque speed curves of nearly all centrifugal pumps have a quadratic shape (counter torque). The pump should be started with closed discharge valve, which reduces the power consumption of the pump during the start. The counter torque of the pump will be minmized which results in a further reduction of the start current. Start currents (I_{a}/I_{n}) during the start of centrifugal pumps are ususally in the range of app. 1,5-3 times of the motor start current at direct on line (I_{DOL}/I_{n}).

In the following chart a typical pump characteristics is shown:

The corresponding power consumption looks like this:

Therefore the power consumption of the pump is 30 % of its maximum power consumption, if the pump is started with a closed discharge valve. (flow rate Q=0). In the following torque chart the torque speed curve of the pump has its usual quadratic shape. It ends (speed n/n_{n} = 1) at a torque requirement of 30 % (this corresponds to the power consumption of the pump).

## Start calculation

motor rated power | P_{n} |
2.000 | kW | ||||

rated voltage | U_{n} |
6.000 | V | ||||

motor rated current | I_{n} |
250 | A | ||||

motor start current DOL | I_{a} |
5 | x I_{n} |
||||

motor rated speed (synchronous) | n_{n} |
1.500 | rpm | ||||

moments of inertia | |||||||

motor | J_{M} |
80 | kgm^{2} |
||||

driven machine | J_{L} |
50 | kgm^{2} |
||||

start voltage | U_{s} |
0,61 | x U_{n} |
||||

start time | t_{s} |
9 | s |

Torque

The starter starts the motor with reduced voltage, 61 % of the rated voltage, in this example (U_{s}/U_{n} = 0,61). The torque speed curve of the motor will be reduced by the factor T_{s}/T_{DOL} = (U_{s}/U_{n} × F)^{2}.

T_{s}/T_{DOL} = (0,61 × 0,91)^{2} = 0,31 (F is a factor dependent on the motor). The torque of the motor must always be higher than the counter torque. The start voltage U_{s}/U_{n} has been determined accordingly. The difference between the reduced motor torque T_{s} and the counter torque is the acceleration torque T_{a}.

## Start time

The start time t_{s} is calculated from the acceleration torque T_{a} and the total moment of inertia J = J_{M} + J_{L} = 80 + 50 kgm^{2} = 120 kgm^{2}.

## Current

The motor current is I_{Mot} = U_{s}/U_{n} × I_{DOL} × F = 0,61 × 5 × 0,91 = 2,8 × I_{n}

**Mains start current:**

U_{n} × I_{s} = U_{s}/U_{n} × I_{mot} => I_{s} = U_{s}/U_{n} × I_{Mot} / U_{n}

I_{s}= 0,61 × 2,8 = 1,7 × I_{n}

The mains start current is therefore much lower than the motor start current.

For other start methods (electronic soft starter, starting reactor etc.) the following is valid: The mains current equals the motor current:

I_{s} = I_{Mot} = 2,8 × I_{n}

For that reason these starting methods create a higher mains voltage drop.

## Piston pumps

Normally piston pumps do not have an especially high moment of inertia with reference to the motor speed. It is usually located in the range of app. 10 - 40% of the moment of inertia of the driving motor. Therefore, piston pump drives can be started with a relatively shot start time of app. 5-15 seconds. Piston pumps can be started nearly without load by pressure release. This is achieved by opening valves and results in a very low counter torque which greatly reduces the start current of the piston pump. Start currents (I_{a}/I_{n}) during the start of piston pumps are ususally in the range of app. 1 - 2 times of the motor rated current (I_{n}). Below you will find a characteristic example for a calculation.

motor rated power | P_{n} |
2.000 | kW | ||||

rated voltage | U_{n} |
6.000 | V | ||||

motor rated current | I_{n} |
250 | A | ||||

motor start current DOL | I_{a} |
5 | x I_{n} |
||||

motor rated speed (synchronous) | n_{n} |
1.000 | rpm | ||||

moments of inertia | |||||||

motor | J_{M} |
150 | kgm^{2} |
||||

piston pump | J_{L} |
35 | kgm^{2} |
||||

start voltage | U_{s} |
0,47 | x U_{n} |
||||

start time | t_{s} |
9 | s |

Torque

The starter starts the motor with reduced voltage, 47 % of the rated voltage, in this example (U_{s}/U_{n} = 0,47). The torque speed curve of the motor will be reduced by the factor T_{s}/T_{DOL} = (U_{s}/U_{n} × F)^{2}.

T_{s}/T_{DOL} = (0,47 × 0,9)^{2} = 0,18 (F is a factor depending on the motor). The torque of the motor must always be higher than the counter torque. The start voltage U_{s}/U_{n} has been determined accordingly. The difference between the reduced motor torque T_{s} and the counter torque is the acceleration torque T_{a}.

## Start time

The start time t_{s} is calculated from the acceleration torque T_{a} and the total moment of inertia J = J_{M} + J_{L} = 150 + 35 kgm^{2} = 185 kgm^{2}.

## Current

The motor current is I_{Mot} = U_{s}/U_{n} × I_{DOL} × F = 0,47 × 5 × 0,9 = 2,1 × I_{n}

**Mains start current:**

U_{n} × I_{s} = U_{s}/U_{n} × I_{mot} => I_{s} = U_{s}/U_{n} × I_{Mot} / U_{n}

I_{s}= 0,47 × 2,1 = 1 × I_{n}

The mains start current is therefore much lower than the motor start current.

For other start methods (electronic soft starter, starting reactor etc.) the following is valid: The mains current equals the motor current:

I_{s} = I_{Mot} = 2,1 × I_{n}

For that reason these starting methods create a higher mains voltage drop.

## Other pumps

Pumps exist in a variety of different designs and types. For the most common ones (centrifugal and piston pump) we have prepared detailled information for the start procedure. Needless to say, our starter can also be used for further pump types. We will gladly provide you with an offer and technical support.

## Extruders

Extruder are (mostly heated) screw conveyors and are mainly used in the plastic processing industry and in the food sector. Sometimes an extruder is also called mixer. The extruder usually has a low moment of inertia; it is normally lower than the moment of inertia of the driving motor. Most of the extruder drives start with a start time between app. 10 and 20 seconds as well as in empty condition (no material in the screw). The empty condition provides a lower counter torque and therefore a greater reduction of the start current. However, a certain counter torque due to residues and crustifications still remaining in the screw has to be taken into consideration. The normal start currents of extruders (I_{a}/I_{n}) are in the range of app. 2-3,5 times the motor rated current (I_{n}). Below you will find a characteristic example for a calculation.

motor rated power | P_{n} |
4.000 | kW | ||||

rated voltage | U_{n} |
6.000 | V | ||||

motor rated current | I_{n} |
500 | A | ||||

motor start current DOL | I_{a} |
5 | x I_{n} |
||||

motor rated speed (synchronous) | n_{n} |
1.500 | rpm | ||||

moments of inertia | |||||||

motor | J_{M} |
200 | kgm^{2} |
||||

extruder | J_{L} |
120 | kgm^{2} |
||||

start voltage | U_{s} |
0,69 | x U_{n} |
||||

start time | t_{s} |
15 | s |

Torque

The starter starts the motor with reduced voltage, 69% of the rated voltage, in this example (U_{s}/U_{n} =0,69). The torque speed curve of the motor will be reduced by the factor T_{s}/T_{DOL} = (U_{s}/U_{n} × F)^{2}.

T_{s}/T_{DOL} = (0,69 × 0,92)^{2} = 0,63 (F is a factor depending on the motor). The torque of the motor must always be higher than the counter torque. The start voltage U_{s}/U_{n} has been determined accordingly. The difference between the reduced motor torque T_{s} and the counter torque is the acceleration torque T_{a}.

## Start time

The start time t_{s} is calculated from the acceleration torque T_{a} and the total moment of inertia J = J_{M} + J_{L} = 200 + 120 kgm^{2} = 320 kgm^{2}.

## Current

The motor current is I_{Mot} = U_{s}/U_{n} × I_{DOL} × F = 0,69 × 5 × 0,92 = 3,2 × I_{n}

**Mains start current:**

U_{n} × I_{s} = U_{s}/U_{n} × I_{mot} => I_{s} = U_{s}/U_{n} × I_{Mot} / U_{n}

I_{s}= 0,69 × 3,2 = 2,2 × I_{n}

The mains start current is therefore much lower than the motor start current.

For other start methods (electronic soft starter, starting reactor etc.) the following is valid: The mains current equals the motor current:

I_{s} = I_{Mot} = 3,2 × I_{n}

For that reason these starting methods create a higher mains voltage drop.

## Shredders

Shredders usually feature controllable hydraulic couplings between the electric motor and the mill. Therefore, the characteristics of the shredder does not influence the start process. We only need to consider the moment of inertia of the motor and the very small moment of inertia of the coupling half at the motor side for the start calculation. This results in a very short start time of app. 5-15 seconds. The start will be carried out almost without load.The coupling generates only a very small counter torque. Therefore the start current can be greatly reduced. Typical start currents (I_{a}/I_{n}) for the start of a shredder range at app. 1 - 1,5 times of the motor start current at direct on line (I_{DOL}/I_{n}). Below you will find a characteristic example of a calculation:

motor rated power | P_{n} |
2.000 | kW | ||||

rated voltage | U_{n} |
6.000 | V | ||||

motor rated current | I_{n} |
250 | A | ||||

motor start current DOL | I_{a} |
5 | × I_{n} |
||||

motor rated speed (synchronous) | n_{n} |
1.500 | rpm | ||||

moments of inertia | |||||||

motor | J_{M} |
80 | kgm^{2} |
||||

coupling | J_{L} |
5 | kgm^{2} |
||||

start voltage | U_{s} |
0,47 | × U_{n} |
||||

start time | t_{s} |
8 | s |

Torque

The starter starts the motor with reduced voltage, 47 % of the rated voltage, in this example (U_{s}/U_{n} = 0,47). The torque speed curve of the motor will be reduced by the factor T_{s}/T_{DOL} = (U_{s}/U_{n} × F)^{2}.

T_{s}/T_{DOL} = (0,47 × 0,9)^{2} = 0,18 (F is a factor depending on the motor). The torque of the motor must always be higher than the counter torque. The start voltage U_{s}/U_{n} has been determined accordingly. The difference between the reduced motor torque T_{s} and the counter torque is the acceleration torque T_{a}.

## Start time

The start time t_{s} is calculated from the acceleration torque T_{a} and the total moment of inertia J = J_{M} + J_{L} = 80 + 5 kgm^{2} = 85 kgm^{2}.

## Current

The motor current is I_{Mot} = U_{s}/U_{n} × I_{DOL} × F = 0,47 × 5 × 0,9 = 2,1 × I_{n}

**Mains start current:**

U_{n} × I_{s} = U_{s}/U_{n} × I_{mot} => I_{s} = U_{s}/U_{n} × I_{Mot} / U_{n}

I_{s}= 0,47 × 2,1 = 1 × I_{n}

The mains start current is therefore much lower than the motor start current.

For other start methods (electronic soft starter, starting reactor etc.) the following is valid: The mains current equals the motor current:

I_{s} = I_{Mot} = 2,1 × I_{n}

For that reason these starting methods create a higher mains voltage drop.

## Mills

Mills exist in a variety of different designs and types. We have prepared detailled information for the start procedure of a shredder. Needless to say, our starter can also be used for further mill types, if the start torque requirement of the mill is not too high. High moments of inertia and therefore long start times do not pose a problem for our starter. If a controlable (f. ex. hydraulic) coupling is mounted between mill and motor, the mill can be started with a very low start current (I_{a}/I_{n}) in the range of app. 1-2 times of the motor start current at direct on line (I_{DOL}/I_{n}). We will gladly provide you with an offer and technical support.

## Other machines

Machines driven by electric motors exist in a variety of different designs and types. For the most common ones we have prepared detailled information for the start procedure. Needless to say, our starter can also be used for further types of machines. We will gladly provide you with an offer and technical support.

## Any questions?

Do you need support to start your drives? We are here to help. Please contact us.