Motor Protection-Basic Explanation
Motor Protection-Basic Explanation
Motor Protection-Basic Explanation
MotorProtectionBasicExplanation
MotorProtectionBasicExplanation
OVERLOADPROTECTION
Overcurrents
An overcurrent exists when the normal load current for a circuit is
exceeded. It can be in the form of an overload or short-circuit.
within the normal circuit path, that is higher than the motors normal
full load amperes (F.L.A.). A short-circuit is an overcurrent which
greatly exceeds the normal full load current of the circuit. Also, as
its name infers, a short-circuit leaves the normal current carrying
path of the circuit and takes a short cut around the load and
just a few of the situations that can be protected against with the
Typically, during the initial half cycle, the inrush current is often
higher than 20 times the normal full load current. After the first halfcycle
the motor begins to rotate and the starting current subsides
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with starting currents and yet protect the motor from sustained
overloads. There are four major types. Each offers varying
degrees of protection.
Fast Acting Fuses
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less of motor F.L.A. for 1.15 or greater S.F. When sized this close
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To allow the motor to start, the MCP must be sized at about 700-800% of the F.L.A. and the thermal
magnetic breaker must be sized at about 250% of F.L.A. Curve 5 clearly shows that breakers sized to
these levels are unable to protect motors against overloads.
Overload Relays
Overload relays, or heaters, installed in motor starters are usually
the melting alloy or bi-metallic type. When properly sized and
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However, if the overload relays are oversized or if the contacts fail to open for any reason (i.e., welded
contacts), the motor is left unprotected. Also, overload relays cannot offer any protection for short-
circuits, and in fact must be protected by fuses or circuit breakers under short-circuit conditions Curve 7
.
.
DualElementFuses
The dual-element fuse is unaffected by the motor inrush current
(Curve 8), but opens before a sustained overload can reach the
motor damage curve (Curve 9).
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430.36, 430.37, 430.55, 430.57, & 430.90). Curve 9 shows that the
dual-element fuse offers excellent overload protection of motors.
FRS-R fuse at 125% of the motor full load current or the next smaller
available fuse size. With a motor having a service factor of less than
1.15, size these same fuses at 115% of the motors F.L.A. or the
next smaller size.
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the fuse at 125%-130% or the next larger size. With this combination
you have the convenience of being able to quickly reset the
large, if the contacts fail to open for any reason or the heaters lose
calibration, the fuses will open before the motor damage curve is
reached.
be reset. Lets examine the choice of either circuit breakers or currentlimiting fuses for motor branch circuit protection.
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motor circuit protectors) are sized with the intent to provide only
short-circuit and ground fault protection for the motor branch circuit
breakers can only be sized for motor branch circuit protection (typically
200% - 250% of motor current) because if they are sized closer,
FRS-R and LPS-RK fuses that can be sized close enough for motor
running overload protection or backup motor running protection.
can be determined from the design of the circuit and the overcurrent
devices involved that the automatic operation of a
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replacing the starter. With properly selected fuses for Type 2 protection,
after the fault is repaired, only new fuses need to be inserted
new factory calibrated fuses are installed in the circuit. The original
level of superior short-circuit protection can be there for the life
of the motor circuit.
going back to the storeroom anyway for parts to repair the fault. If
let-through energy by the circuit breaker has not caused the loss
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very best protection. The best motor branch circuit protection can
be judged by (1) reliability - its ability to retain its calibration and
speed of operation over its lifetime, (2) current-limiting protection its ability to provide Type 2 no damage protection to the motor
starter, and (3) safety - its ability to meet a facilitys safety needs.
Modern current-limiting fuses are superior to circuit breakers for
motor branch circuit protection.
(1) replace the fuses or (2) reset the circuit breaker and replace the
starter (and maybe the circuit breaker, too).
From the above data, it can be seen that 44% of motor failure
problems are related to HEAT.
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and stator losses (core losses), will continue to increase until the
under the conditions specified for the Service Factor of the motor.
Conditions include such things as operating the motor at
rated voltage and rated frequency.
previously for all practical purposes, insulation life is cut in half for
every 10C increase over the motors rated temperature.
Voltage Unbalance
When the voltage between all three phases is equal (balanced),
current values will be the same in each phase winding.
When the voltages between the three phases (AB, BC, CA)
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Power factor correction capacitors not the same. . .or off the
line.
Insulation Life
The effect of voltage unbalance on the insulation life of a typical Tframe
motor having Class B insulation, running in a 40C ambient,
loaded to 100%, is as follows:
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Insulation Classes
The following shows the maximum operating temperatures for different
classes of insulation.
Class A Insulation 105C
Class B Insulation 130C
Class F Insulation 155C
Class H Insulation 180C
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In some cases, one device opens, and shortly thereafter, the second
device opens. In either case, three-phase motors are protected
against balanced voltage overload conditions.
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the motor is carrying two times that of the other two phases. Without an
overload device in the phase that is carrying two times the current in the
other two phases, the motor will burn out.
The National Electrical Code, Section 430.36 requires that
when fuses are used for motor overload protection, a fuse shall be
inserted in each phase. Where thermal overload devices, heaters,
etc. are used for motor overload protection, Table 430.37 requires
Since 1971, The National Electrical Code has required three overload
125% of the motors full-load current rating. Since all motors are not
necessarily fully loaded, it is recommended that the actual current
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Normal Maximum
100 amperes.
enough to drive the load. The motor will continue to try to drive
the loaduntil the motor burns outor until the properly sized
*When sizing to the actual running current of the motor is not practical, an
economic analysis can determine if the addition of one of the electronic
black boxes is financially justified. These electronic black boxes can
sense voltage and current unbalance, phase reversal, single-phasing, etc.
**Instantaneous only trip breakers are permitted to have time-delay. This could
result in more damaging let-through current during short-circuits.
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upon the actual running current of the motor under its given loading,
rather than the nameplate current rating.
SinglePhasing Causes Are Numerous
One fact is sure: Nothing can prevent or eliminate all types of singlephasing.
contact kits sold each year confirms the fact that worn motor
on smaller size motor starters that are protected by noncurrentlimiting overcurrent protective devices.
3.Damaged
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into terminals and lugs suitable for use with copper conductors
or copper-clad conductors only.
8.Open winding in motor.
times the normal current draw of the motor. The increase can be
as much as 2 times (200%) because of power factor changes.
Where the motor has a high inertia load, the current can approach
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SINGLEPHASING ON SECONDARY
NORMAL CONDITION SINGLEPHASING CONDITION
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overload relays will safely clear the motor from the power supply.
However, should the overload relays or controller fail to do so,
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the user who purchases electrical power. When primary single phasing
occurs, unbalanced voltages appear on the motor circuit,
the overload relays will protect the motor. However, if for some reason
the overload relays or controller fail to function, the LOWPEAK
or FUSETRON dual-element fuses properly sized to
provide backup overload protection will clear the motor from the
power supply.
some cases, protective devices which sense only current may not
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capacity than larger horsepower rated motors and are more likely
to be protected by conventional motor running overload devices.
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