The Three Levels of Motor Starter Controls

By ABB | February 20, 2025
Read Time: 6 Minutes

Anyone who has bought tools from a department store will recall that, for most of their commonly used tools, the options were presented as "good, better or best.” It’s a handy framework for helping guide buying decisions of not only tools but any product that comes in a range of quality levels.

The “good, better, best” classification is also valuable when considering the appropriate configuration of 480 V, 3-phase motor starting systems. The decision-making process for these systems has far more variables to consider compared to selecting a wrench or drill, but the three-level framework is still a good way to scope your system design and begin to identify the optimum components to meet your needs.

Regarding motor starting systems, it might be better to replace the terms “good, better, best” with essential (basic protection), enhanced (increased monitoring and protection) and advanced (digital connectivity and cloud monitoring). Each of the higher levels includes the capabilities/functions of the lower level(s), building on their foundation with additional features and functions.

In addition to the need for specific features or functions, another factor that drives control panel builders to the more-advanced control systems is amperage. At the lower amperages, an essential or enhanced system is appropriate, although even at 590 A, an essential system may be all that’s needed. But at amperages higher than 590 A, advanced systems are more common due to the cost of the equipment and the monitoring implemented to protect those assets.

Essential Level Motor Starter Controls

Most standard motor starting applications only require the combined functions of a branch circuit disconnect, short circuit protection, motor overload protection, and control over the motor branch circuit. Standard applications include most pumps, fans, HVAC and conveyors, as well as other standalone electric motor-driven equipment.

In addition to the standard required buttons, controls, and indicators, every motor starting system requires short circuit protection that can be provided by a molded-case circuit breaker, fuses or manual motor starter. An enclosed safety switch located at the motor is also required not only to enable quick and easy disconnect of the motor, but also a local lockout point for safe maintenance.

Current in a simple system may be controlled by either a contactor or soft starter. The choice between the two is driven by how the motor is used. Motors that operate continuously require only a contactor. They are a simpler and more cost effective solution when compared to a soft starter, but also deliver full current at startup, which can create wear and tear on the motor or system if used in the wrong application.

Conversely, soft starters give more refined control over the current, torque and perhaps most importantly, acceleration. For applications where the motor is regularly cycled on and off, the soft starter ramps up the current gently. In operation, the soft starter can be adjusted to the needs based on multiple variables, delivering only the required current for a specific application. This reduces energy use and related costs for the specific application and can greatly extend motor life.

Enhanced Level Motor Starter Controls

Enhanced systems enable panel builders to provide a more tailored solution, while helping provide increased safety and protection for personnel and equipment. This is accomplished by incorporating sensors and/or additional protective devices. Thermistor motor-protection relays or phase- or voltage-monitoring relays are examples of adding enhanced protection and monitoring to a system.

Additionally, motor/system amperage drives control panel builders to more capable control systems. Enhanced-level selections are more common in higher amperage systems due to the increased costs of downstream equipment and increased costs associated with larger power consumption. Considering the higher cost of operation, and in the unfortunate event equipment repairs and/or replacement, the implementation of monitoring relays is recommended.

Incorporating monitoring relays provides additional protection outside of essential architecture. Thermistor motor-protection, phase, voltage and current monitoring relays are a few examples of adding enhanced protection and monitoring to a system. These relays can detect events like under- and over-voltage, phase imbalance, or current loss that are known to directly impact motor performance. Avoiding unexpected shutdowns and increasing system or process reliability, directly contributes to an OEM’s profit, and is the fundamental reason for investing in an enhanced level of protection.

Advanced Level Motor Starter Controls

The advanced level builds on the capabilities of an enhanced system, with the addition of digitalization. The motor starting system gains cost saving insights, with the ability to alert process and maintenance managers about any problems. Now, rather than sending a technician to the site of a fault to diagnose the problem by checking an HMI or local display, the needed data is available via the cloud to anyone with the appropriate access rights and credentials.

Beyond learning that a circuit breaker tripped, you will have information at your fingertips about what caused the trip. Whether it was an arc flash, locked motor, overload or other issue, you instantly understand the problem and can more quickly dispatch the appropriate personnel to restore operations.

This level of control and monitoring is excellent for OEMs who are focused on data driven improvements and reducing downtime to the lowest levels possible.

Selection Tools

Awareness of the three levels is helpful when concepting a motor starting system, however, selecting the specific components can be challenging. Control panel device OEMs and distributors help simplify the process with various reference documents and configurators.

View the ABB motor starting and protection selector tool.

View the ABB low voltage protection selector tool.

Choosing a Motor Starting System Level

As you move from the essential to advanced levels, it’s important to consider that added system sophistication means more devices which means more panel space. Where compact panels are required, panel builders may have to scale back on the number of components and level of panel capability.

Of course, as the level of the motor starting system capabilities increase, so does the cost. Those higher costs are easily offset by the value the system returns, including:

Reduced downtime
Protected high-value assets
Maximized machine output
Optimized machine performance

For basic applications where downtime doesn’t create a major problem, a lower-cost essential system will serve your needs well. For motor starting that requires more sophisticated features and functions, the added cost of an enhanced or advanced design is more than recovered in reduced risk to people, processes and assets..

Understanding Your Needs

Although this guide can be a helpful resource, understanding what motor starting controls will best fit your organization isn’t always easy. Maximizing your assets’ performance and lifespan is top-of-mind, but it’s also important to consider your budget into the decision-making process. Wesco can help make that process easier.

Our technical experts will take the time to understand your unique situation and goals and recommend solutions that can meet those needs. We can provide valuable training to ensure you get the most out of your investment and connect you with world-class manufacturers – like ABB – if additional training or technical expertise is needed.

Whether you’re looking to minimize downtime, better understand your operations or simply protect your valuable assets, finding the right motor starting control is vital. Reach out to your Wesco sales rep for more information.

Wesco’s partnership with ABB improves the safety, reliability and efficiency of our customers’ projects.

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ABOUT THE SPONSOR

This article was brought to you in partnership with ABB.
As a leader in electrification and automation, ABB is enabling a more sustainable future. Their solutions connect engineering know-how and software to optimize how things are manufactured, moved, powered and operated. Building on more than 140 years of excellence, ABB’s 105,000 employees are committed to driving innovations that accelerate industrial transformation.