MOTOR PROTECTION

INTRODUCTION

When applying protective relays to motors or any other equipment, we always ask how
much protection is enough. The answer depends on rewind cost, loss of production,
effect on downtime, new versus old installation, need for communication, metering,
control and the consequences of a motor failure on the electrical system and process.

This paper presents an overview of motor hazards and a discussion of detection and
protection options. Basler relay models are offered with typical setting value ranges
and considerations to help designers and users select Basler relays for motor protec-
tion. Most of the protection functions apply to squirrel cage, wound induction motors
and synchronous motors. Additional protection is usually provided for synchronous
motors and will be mentioned in this document.

OVERVIEW OF MOTOR HAZARDS

Motor protection is a challenge because there are so many different things that can go
wrong with a motor and its associated load:

Motor induced
• Insulation failure (within the motor)
• Bearing failure
• Mechanical failure
• Synchronous motors-loss of field

Load induced
• Overload and underload
• Jamming
• High inertia

Environment induced
• High ambient temperature
• High contaminant level or blocked
ventilation
• Cold or wet ambient conditions

Source induced
• Loss of phase or phases
• Voltage unbalance
• Overvoltage
• Undervoltage
• Phase reversal
• Out of step condition resulting from system disturbance

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Operation induced
• Synchronizing or closing out of phase
• High duty cycle
• Jogging
• Rapid reversing

PROTECTION

Stator Faults

Phase Fault Overcurrent Protection

Phase to phase and three phase faults are usually detected with nondirectional instan-
taneous or definite time overcurrent relays. If the available 3-phase fault current is a low
multiple of the relay setting (weak system), quick pickup is not assured. Differential
relaying should then be considered. Instantaneous relays are typically applicable when
the motor rating is less than one-half of the supply transformer KVA rating.

The instantaneous phase relay should be set at no less than 1.6 times the locked rotor
current using the value of locked rotor current at maximum starting voltage. This setting
also assumes the relay is sensitive to the transient overreach (DC offset) of an asym-
metrical fault. Lower settings are possible if the relay disregards the transient compo-
nent or if a time delay longer than the transient time (6-15cy) is added. Verify that the
minimum 3-phase fault current at the motor terminals is at least 3 times the relay setting.
Figure 1 illustrates the relay settings in relation to the starting current and the minimum
short circuit current.

Figure 1: Stator short circuit protection with 50 or 50P element.

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Differential Protection

Differential protection is used on motors where the available short circuit current is close
to the value of locked rotor current. It is also frequently used on very large motors be-
cause of its greater sensitivity. Differential protection is always preferred; however, it is
generally more costly than instantaneous relaying because all six leads must be
brought out of the motor and additional relays may be required.

SELF BALANCING
The most economical approach is self-balancing differential as shown in Figure 2. Both
ends of the winding are passed through a toroidal current transformer and connected to
a 50 device. This CT has a maximum opening around 8 inches that may preclude its
use on larger motors.

Figure 2: Self balancing differential.

With a fixed ratio of 50:5 and a sensitive instantaneous overcurrent, the self-balancing
differential provides a pickup around 5 amps of primary current. This scheme is self-
balancing and produces no current for starting or load variation and, because there is
only one CT per phase, there is no concern about matching CT performance to elimi-
nate unequal CT saturation. CT saturation is likely for large fault currents but is slow
enough to allow the instantaneous relays to operate.

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PERCENTAGE RESTRAINT DIFFERENTIAL
When the toroidal CT cannot be used, the percentage restraint differential circuit (Figure
3) must be applied. Typically, all 6 CTs are the same ratio and accuracy class. A 2-
winding differential relay can be applied with equal currents flowing in the restraint
windings for normal load, starting, and external faults. For internal phase or ground
faults, all of the current will flow through the operate windings. The scheme will also
protect for cable faults between the motor and the motor breaker (52) by using the line
side CTs of the breaker. If the motor and motor breaker are supplied separately, be
certain to match the CT ratios and accuracy classes when specifying the equipment.

Figure 3: Conventional percent differential relay.

Ground Fault Protection Ground Sensor 50G

The preferred and most sensitive method to detect stator ground faults is with a ground
sensor CT. All three phase leads from the motor are passed through the opening of a
toroidal current transformer supplying the instantaneous overcurrent 50G relay shown in
Figure 4. This arrangement leaves only the ground fault zero sequence currents in the
CT. The typical application calls for a 50:5 CT ratio regardless of the size of the motor.
Primary pickup values in the range of 4-12 amps are typical. If more sensitive settings
are required, time delay may be necessary to avoid nuisance trips due to zero-se-
quence cable capacitance current flow during external faults.

The ground fault sensor connection may be the only scheme providing sufficient sensi-
tivity when the supply system is high-impedance grounded. If a large ground fault
current is available in a solidly grounded system, the 50G relay must operate before the
low ratio CT saturates. Fortunately, the low impedance of solid state relays reduces the
CT burden.

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 Figure 4: Ground sensor relay and residual ground connection.

RESIDUAL CONNECTION 51N

For larger motors, where the conductors will not fit through a ground sensor CT, the
residual ground connection, shown in Figure 4, must be used. The ground fault relay
sensitivity is limited by the phase CT ratio. Since unequal CT performance must be
expected, a 51 relay is used to avoid tripping on false residual current.

This 51N relay must be coordinated against the 51G system ground protection relay
(typically in the supply transformer neutral). In solidly grounded feeder applications,
where the ground fault is usually high and the CT quality good, an instantaneous relay
(50N) can be added to accelerate the tripping. This relay should be set at 4 x Full Load
Current or higher to avoid tripping on starting.

Thermal Damage

Locked Rotor Protection

When a motor stator winding is energized with the rotor stationary, stator winding cur-
rents may range from three to seven times rated full-load value depending on motor
design and supply system impedance. Actual values of locked rotor currents are part of
the motor data supplied by the motor manufacturer. Heating in the stator winding,
proportional to I2t, is 10 to 50 times rated conditions and the winding is without benefit
of the ventilation normally produced by rotation of the rotor.

Depending on the design, a motor may be stator limited (thermally) or rotor limited
(thermally) during locked-rotor conditions. The motor manufacturer can furnish the
allowable locked-rotor time only after the motor design is completed. This is given as
time at rated locked-rotor current starting from either rated ambient temperature or rated

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operating temperature also referred to as cold stall time or hot stall time. It also is given
as part of the motor time-current curve defined by IEEE Standard 620-1996.

Starting times depend on motor design and load torque characteristics and must be
determined for each application. Although starting times of 2 to 20 seconds are com-
mon, high inertia loads may take several minutes to bring to full speed. Starting time is
increased if bus voltage is less than nominal.

SHORT START TIMES

When the margin between the maximum start time and the hot stall time is at least 2 to
5 seconds, locked rotor protection can easily be achieved with a definite time
overcurrent (50TP) as shown in Figure 5. By setting this relay close to the Full Load
Current, good protection against failure to accelerate is obtained. To prevent the 50TP
relay from operating under temporary overloads once the motor is running, it is super-
vised by the 62 timer. The time delay on the 50TP should be set at the maximum start
time plus 25% of the thermal limit margin time. The delay on the 62 timer should be set
slightly higher than the 50TP time delay to allow a one or two second window for the
locked rotor protection to operate. This protection is easy to implement in the Basler 851
and MPS multifunction relays.

Figure 5: Locked rotor protection – Short starting times.

Another approach often used with single-function relays is shown in Figure 6. The 50S
or 12 (speed switch) device is used to supervise the 51S relay which is set for locked
rotor protection. The speed switch is set at 10%-50% of full speed and the 50S is set
about 85% of Locked Rotor Current (at minimum allowable voltage). The 51S should be
set between the hot stall time and the start time. The 51P relay is a second 51 relay set

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for running thermal overload. If no transient overloads are expected, the 51P and 50S
relays may not be required. The 51S will then provide starting and running protection.

Figure 6: Locked rotor protection short start times – Single function relays.

LONG START TIMES

The starting current of a motor falls below the locked rotor value when the rotor begins
to turn. Therefore, the stator heating is reduced when the motor accelerates. For some
large induction motors with low starting voltages or with high inertia loads and long
starting times, the starting time may exceed the allowable locked-rotor time without
excessively heating the rotor.

When the start times approach or exceed the maximum safe stall time, protection
against locked rotor requires a 51S relay that must be prevented from tripping soon
after the motor has successfully started as shown in Figure 7. (The 51S contact is likely
to close due to the intensity of the starting current following the locked rotor current.) A
speed switch set at 10%-50% of nominal speed or a 50S relay set at about 85% of
Locked Rotor Current (at minimum voltage) are commonly used to supervise the 51S
relay. The 51S curve must be set to operate below the hot stall time. When the motor
starts successfully, the 12 or 50S device drops out and prevents the 51S from tripping
the breaker.

If the motor starts but does not accelerate to nominal speed, this protection may not trip
since the 51S relay is cut out early in the start sequence. The failure to accelerate would
have to be detected by the thermal overload 51P, set for running conditions (shown in
Figure 6). However, the 51S may be used to alarm for subsequent overloads, including
failure to accelerate once the motor has started.

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 Figure 7: Locked rotor protection – Long start times.

Thermal Overload Protection

STATIC REPRESENTATION
The life of the motor is reduced if the winding temperatures are allowed to exceed their
insulation class levels for a significant time. It is usually assumed that for every 10
degrees C above the design temperature limit the life of the motor is reduced by a
factor of 2.

When normal cooling and ambient temperatures are present the temperature of the
stator winding is directly related to the stator current, and the running thermal overload
limit can be stated on a time-current plot as recommended in IEEE STD 620. Running
thermal overload can thus be provided by an overcurrent relay which has a time-current
characteristic similar to the thermal overload limit. The Minimum Pick Up of this relay is
the continuous overload specification of the motor, i.e. the (Full Load Current)x (Service
Factor). The characteristic is usually an I2t curve. The time dial is chosen to coordinate
against the thermal limit and allow short duration overloads predictable from the pro-
cess analysis.

Figure 8 shows two IEEE device numbers (51 or 49). These devices may have nearly
identical static characteristics, but will differ in their dynamic response and, therefore, in
their ability to track the motor temperature over time.

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 Figure 8: Thermal overload – Running.

DYNAMIC CONSIDERATIONS
In order to force the static characteristic to pass through point P in Figure 8, the user
adjusts the time dial in a 51 relay or the time constant in a 49 relay. These terms imply
that the dynamic response of a 51 element is linear, whereas the 49 element has an
exponential response. When the 49 element, found in dedicated motor relays (as op-
posed to general purpose overcurrent relays) takes the load level into account, it be-
comes a realistic thermal model of the motor. In this case, the 49 element does not reset
to zero when the current is below the overload limit (as does the 51 relay) but settles at
percent of pickup value corresponding to the used thermal capacity at the given load
level.

Figure 9 compares the 51 and 49 response for nearly identical static settings. The 51
relay is a more conservative choice since it tends to trip faster than the 49 relay. The 51
is an acceptable choice for any process where temporary overloads are abnormal. The
49 is preferred when the process requires the tolerance of temporary overloads.

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 Figure 9: Compare 51 and 49 dynamic response.

TEMPERATURE SENSING
Motors are typically cooled by means of a rotor-mounted fan blade that forces air
through the motor frame while the motor is running. Thermal limits and temperature rise
are based on this cooling functioning as designed with a known level of ambient air
temperature. If normal cooling is blocked, overheating at normal load current is pos-
sible. The only protection will be temperature-measuring devices located in the motor
such as RTD’s or thermocouples. Basler MPS100 and 200 series relays provide this
protection with inputs from RTD’s or thermocouples imbedded in one or more of the
winding slots.

The MPS relays monitor the RTD resistance and accept two setting levels for each
monitored point: a low setting for alarm and a high setting for shutdown. The specific
settings are derived from the winding insulation class, defined in NEMA MG-1, and
judgment based on the plant operating conditions. The recommended setting for alarm
temperature level is the sum of the maximum ambient, plus 10 degrees hotspot allow-
ance, plus the full load temperature rise. This value should be below the insulation
class rating. The trip level can be up to 50 degrees C above the class rating if the pro-
cess is critical, since the loss of life from occasional short overload periods is insignifi-
cant. Setting the trip temperature at the insulation class limit is a conservative setting.

Repetitive Starts and Jogging Protection

In repeated starting and intermittent operation very little heat is carried away by the
cooling air produced by a turning rotor. Repeated starts can build up temperatures to
dangerously high values in either stator or rotor windings unless enough time is pro-
vided to allow the heat to be dissipated.

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The NEMA MG1-1993 (Motor Guide) sections 12.50, 20.43 and 21.43 provide guide-
lines for typical installations. These standards allow two starts in succession, coasting to
reset between starts with the motor initially at ambient temperature, and for one start
when the motor is at a temperature not exceeding its rated load operating temperature.
This assumes that the applied voltage, load torque during acceleration, method of
starting, and load inertia are all within values for which the motor was designed. The
application and protection of motors having abnormal starting conditions must be
coordinated with the manufacturer.

The Basler MPS relays have protection for too many starts. The user selects a setting for
number of starts and time period to match manufacturer recommendations. Exact
determination of starting frequency is a very complex calculation that is affected by
many factors including motor size, enclosure, voltage, ambient temperature, inertia,
load-speed-torque characteristic, and running time. Motor restarts will typically depend
more on the stator thermal capacity than on rotor thermal capacity and stall time. The
best rule, by far, is to minimize the number of starts since each start reduces the life of
the motor.

Motors protected by Basler MPS relays include a protective element for thermal over-
load protection. Unlike their inverse time electromechanical counterparts, these relays
can remember the stored value of the “accumulated thermal capacity”. Motor starting
alone may use up 50%-65% of the available thermal capacity. These multifunction
devices also recognize a stopped motor will cool slower than a running motor because
there is no cooling air produced by the rotor. Therefore, it is possible that attempting to
start a motor twice in rapid succession may cause a protective trip on thermal overload.
However, we should still adhere to the manufacturer’s recommendation for frequent
starts.

Unbalance Protection

CAUSE AND EFFECTS

Unbalance in the feeder phase voltages or motor winding impedance will cause unbal-
anced currents to flow to the motor. The negative sequence current from the unbalance
will cause rotor heating and additional copper losses in the stator windings due to an
increase line current. Due to the low negative sequence motor impedance the % nega-
tive sequence current is typically about five times larger than the % negative sequence
voltage. Unbalanced conditions must be detected to avoid thermal damage to the
running motor.

DETECTION
Although the current unbalance is the parameter directly responsible for the tempera-
ture increase in the motor, two detection methods are available: voltage and current
unbalance.

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Voltage Sensing (47)
This method has the advantage of detecting the unbalance voltage for a complete bus
to which several motor loads may be connected, but has the disadvantage of requiring
that all motors be tripped when an unbalance exceeds the setting. The bus voltage
unbalance may be tolerated by a motor if its load is lighter at the time of the unbalance.

Two common measuring techniques have been implemented: the NEMA defined
unbalance and negative sequence voltage measurement. The NEMA definition, found
in MG1 is: %Unbalance=(Max Deviation from Avg.)/Avg. The negative sequence volt-
age is usually defined in % of nominal voltage.

Current Sensing (46)

Current unbalance is measured in the motor feeder itself and has the advantage of
being adapted to each motor. It is easy to implement in multifunction and dedicated
motor protection relays. Measuring algorithms include the true negative sequence
measurement and the difference between the maximum and minimum phase currents.

SETTINGS

Voltage Relay
NEMA recommends in MG1 that continuous voltage unbalance should never exceed
5%. For small to moderate unbalance, the NEMA and negative sequence formulae
yield approximately the same result. A voltage unbalance relay can, therefore, be set at
an MPU of 5%. To set the time delay to trip, consider the thermal damage by the corre-
sponding negative sequence current. To this voltage unbalance of 5% corresponds an
I2 of about 25%, provided the voltage is measured at the motor terminals. Assuming the
motor can tolerate I2t=K, the maximum time delay for a 5% voltage unbalance and
K=40 would be 640 seconds. Although no standard exists for motors, a value of K=40
is often used.

Unfortunately the 47N relay does not offer an extremely inverse characteristic that could
emulate the I2t characteristic. It is suggested to base the time delay on the worst case
expected unbalance, i.e. open phase in the motor feeder cable. The positive and nega-
tive sequence currents are then equal (1pu at full load). The trip time for this unbalance
condition would thus be equal to K (I2 =1pu). For K=40, the maximum delay for an
open phase should be 40 seconds. If the relay uses a definite time, this will have to be
the setting, and result in overprotection if the unbalance is less severe. If the timing
curve is inverse, the time dial should be selected to cause tripping when the voltage
unbalance, at the motor terminals, corresponding to the 1 pu I2 is equal to 20%.

In most applications the voltage seen by the 47N will not come from the motor terminal,
but from the bus. Depending on the size and nature of other loads (static Vs motor)
connected to the bus, the 47N may not sense the open phase in the motor feeder.
Therefore, 47N application requires careful analysis.

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Current relay
In order to relate the current unbalance MPU setting to the 5% NEMA voltage unbalance
limit, it is necessary to establish the correlation between the current unbalance algo-
rithm and the unbalanced voltage. For a negative sequence type element, the I2 % MPU
setting is approximately 5 times the % voltage unbalance for the worst case nominal
load condition. For other algorithms, the Instruction Manual must be consulted.

The current unbalance measuring elements have an I2t=K like characteristic which
makes the time delay settings easier to apply than with the voltage relay. If no other
information is available choose K=40. The worst case unbalance occurs for an open
phase at full load. The negative sequence current is then equal to the positive se-
quence current, i.e. 1 pu. The time dial should be set to cause tripping in 40 seconds in
this case where K=40.

Abnormal Supply

According to the NEMA MG1-1993 section 20.45, motors are generally expected to
operate successfully under running conditions at rated load with a variation of plus or
minus 10% of rated voltage, plus or minus 5% of rated frequency, or a combination of
the two, provided the sum of the absolute values of the deviations does not exceed
10% and the frequency variation does not exceed plus or minus 5%. For synchronous
motors, rated excitation current must be maintained.

Figure 10 shows the effects of voltage and frequency variations on induction motor
characteristics.

Given these limits, there is no one protective device that can make a direct determina-
tion of these quantities simultaneously. However, variation in voltage or frequency will
usually result in an increase in stator winding temperature over a long period of time.
Direct temperature measuring devices, such as RTDs, will detect the change and pro-
vide adequate warning or tripping, provided the abnormal condition is not extreme.

A large induction motor rotating at rated speed or a large synchronous motor with fixed
excitation may be approximated at steady-state conditions as a constant
kilovoltampere device for a given shaft load, and, therefore, current variations follow
voltage variations inversely. An undervoltage condition will result in an overcurrent
condition. Single phase over- or undervoltage is likely to be detected by unbalanced
voltage or current protection if so equipped. Three-phase undervoltage will be pro-
tected by thermal overload protection since the current will be higher than normal for a
given load. Voltage relays, per se, are generally not always sensitive enough to provide
reliable protection, especially on busses where several motors are connected, since the
spinning motors will support the voltage on the low or missing phase. However, an
inverse time or definite time undervoltage relay is recommended to trip when a pro-
longed undervoltage condition exists and as a backup. Pickup settings of 0.8-0.85 per
unit will provide adequate protection. The time delay should be set slightly longer than
the maximum starting time with minimum allowable voltage to ensure undervoltage will
not trip for a start.

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 Figure 10: The effects of voltage and frequency variation on induction-motor
characteristics.

A separate concern of undervoltage is its impact on starting a motor. Unlike a running

motor, low voltage on starting of a motor produces lower starting current and, hence,
lowers torque. If the torque is too low to overcome the torque requirements of the load,
the motor will not successfully start. The MPS210, equipped with control functions,
checks the supply voltage before starting; if the voltage is too low, the relay prevents
starting.

Voltage Drop During Starting

Another concern during motor starting is the voltage drop caused by the locked rotor
current flowing through the supply transformer. A weak system or undersized supply
transformer will only aggravate the situation. When the supply voltage decreases dur-
ing start, then so does the current and starting torque. If there are other running motors
on the bus, the reduced voltage will cause higher currents and further increase the
voltage drop. Should the voltage drop low enough, it is possible for the motor torque to
be low enough to prevent a successful start of the motor.

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Whether motor starting or system weakness is the problem, reduced voltage may cause
trouble at times other than during acceleration. Reduced voltage running will cause
overheating with time. Short term voltage dips may also cause an already running
motor to stall. The user should also consider the effect of trying to start more than one
motor at the same time, which will only aggravate the undervoltage condition. Many
motors use motor contactors powered by the ac line voltage. Reduced voltage could
drop out the motor contactor and cause an already running motor to be dropped off line
when the motor contactor drops out.

Voltage drop calculations should be performed to determine what the motor voltage
conditions will be during starting. The calculation should be checked at maximum and
minimum expected bus voltage before start. In a properly designed power system, with
a good match between bus and motor design voltages, starting voltage dips of 15%-
20% are not uncommon. Designers frequently assume that an accelerating motor draws
its full voltage inrush current and calculate the upstream voltage drops on that basis.
Clearly, any voltage drop in the supply system means that full voltage and correspond-
ing inrush current cannot be present.

Reduced Voltage Starting

When voltage drops are excessive during starting, reduced voltage starting techniques
may be employed. These add to the motor controls but may be less expensive than
changing transformers and cables. All of these techniques use some method to apply
partial voltage to the motor during the initial starting sequence, then when the motor is
at partial speed, full voltage is applied to finish the start sequence. The Basler MPS210
supports reduced voltage starting.

Wye-Delta starting applies a reduced voltage at the beginning of the start sequence
with a wye connection of the motor and then changes to the delta connection of the
motor to complete the start sequence. This arrangement reduces starting torque and
voltage drop on the motor bus.

Another method of reduced voltage starting is autotransformer start. The autotrans-

former is connected in wye with the supply voltage and, during starting, the tapped
partial voltage is applied to the motor. When the starting contactor makes its transition,
the partial voltage source is opened, and full supply voltage is applied. Detailed de-
scriptions of these schemes may be found in the Instruction Manual for the Basler
MPS210 relay.

Frequency Protection

Frequency in excess of rated frequency but not in excess of 5% over the rated fre-
quency without a corresponding voltage increase is not considered to be a hazardous
condition for synchronous or induction motors provided the driven equipment does not
overload the motors at the higher frequency.

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At decreased frequency without a corresponding voltage drop, the flux requirements of
a motor are increased, thus increasing the hysterisis and eddy current losses and
heating. Sustained operation at 5% below nominal frequency and rated or overvoltage
is not permissible per NEMA MG1-1993 section 20.45. Protection against this type of
operation is typically thermal overload or RTD temperature measurement. However,
more refined protection can be obtained with the Basler 81O/U over/under frequency
relay. Time delay settings of 20-30 seconds will allow it to ride though transient condi-
tions without nuisance tripping.

Many utility substations are equipped with underfrequency load shedding relays to
reduce the system load during a loss of generation and subsequent decay in system
frequency. Large motor loads connected to the distribution substation may interfere with
the normal operation of the underfrequency relay by allowing it to see a decline in
frequency without a complete loss of voltage. This can happen when the distribution
bus is disconnected from the supply transformer and the underfrequency relay is con-
nected to the distribution bus. The relay will then see the residual voltage from the
motor load and may operate incorrectly. Relocating the underfrequency voltage trans-
former to the high side of the supply transformer or adding additional time delay to the
underfrequency time delay may solve the problem.

Mechanical or Process Protection

Undercurrent

We generally think of protective relays as devices that protect electrical equipment. In

the case of motor protection, there may be times when they are used to protect the
process. For example, the water pumping station that is intended to operate continu-
ously at 90% of full load current. If the pump were to be damaged, lose its prime, or the
shaft break, the load on the motor would be drastically reduced. The Basler MPS relay
monitors for undercurrent or under power conditions. These elements are not in service
until the motor is running and can be set to detect these loss-of-load conditions to alarm
or trip.

Bearing Protection

To minimize damage caused by bearing failure, protective devices should be used to

sound an alarm or de-energize the motor. Bearing protective devices responsive to one
or more of the following conditions may be included:

(1) Low oil level in reservoir: (device 71) level switch

(2) Low oil pressure: (device 63) pressure switch

(3) Reduced oil flow: (device 80) flow switch

(4) High temperature: (device 38) thermocouples or resistance temperature detector

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(5) Rate of temperature rise

(6) Vibration (used on motors with anti-friction bearings in place of thermal devices)

Large motor bearings are usually monitored by a resistance temperature detector (RTD)
which can be used as one of the inputs to the Basler MPS200 or 210 relay. The dual-
setpoint of the RTD function of the MPS allows for alarm and trip settings at two different
temperatures.

BUS TRANSFER AND RECLOSING

Many motor busses are critical to process or plant operation and, therefore, must be
maintained if at all possible. For static loads, high speed reclosing or transfer to an
alternate source is appropriate. Motor loads require special considerations. When the
motor is disconnected from the voltage supply, the voltage at the motor terminals does
not go to zero. The machine generates a voltage at its open-circuited terminals that
decays with time. A fast reclose applies the full bus supply voltage in series with the
residual motor voltage, producing a total winding voltage that can be dangerously
high. Capacitors in the circuit only make the situation worse.

A second complication is the decay in motor speed with respect to the supply system.
The frequency of the residual voltage in the motor will be a decaying value of frequency
as the motor begins to slow down. The worst case could be nearly 2.0 per unit voltage
and 180 degrees out of phase with the supply voltage. The possibility of damage exists
for local reclosing of the motor, high side reclosing from the utility, transferring to an
alternate source, or reduced voltage motor starting; they all mean the motor will be re-
energized after some dead time and the same principles apply.

Parallel Transfer

Parallel transfer is a method of transferring process loads from one source to an alter-
nate source. In this method, the bus tie breaker is closed before the normal source
breaker is opened. This method has gained wide acceptance because the transient on
the motor bus is eliminated, assuming the two sources are in phase. However, the bus
system designed for this transfer method may violate the interrupt rating for the circuit
breakers and the short-term withstand ratings of the normal and alternate source power
transformers. A fault in a motor or its leads occurring during the time the sources are
paralleled may produce fault current levels in excess of the circuit breaker ratings. The
probability of this happening may be viewed as small; however, the consequences of
such a fault should be thoroughly understood before the parallel transfer system is
used.

Parallel transfer requires a high-speed sync-check relay such as the Basler BE1-25 as
shown in Figure 11 to ensure that the phase difference across the bus tie breaker is
within acceptable limits prior to transfer. Without this permissive relay, a large phase
angle would cause a power surge through the bus system that could cause damage to

17
the bus system components. An angle setting of 15-25 degrees with no time delay may
be used.

Figure 11: High-speed sync-check relay.

Fast Transfer

Fast transfer involves opening the normal source breaker prior to closing the tie
breaker, thus avoiding the problems associated with parallel transfer. This method is
intended to minimize the transfer time between sources. However, the bus must always
be completely disconnected from both sources for a short period of time.

One technique involves issuing simultaneous trip and close commands to the normal
source and bus tie breaker. If the tripping breaker is abnormally slow, the sources can
be briefly paralleled, introducing the problems of parallel transfer. Another method
involves using a “b” contact from the normal source breaker to close the bus tie
breaker.

Especially during abnormal transient conditions, supervision of the fast transfer requires
a high-speed sync-check relay such as the Basler BE1-25 to ensure that the phase
angle between the motor bus voltage and the alternate source voltage is within accept-

18
able limits prior to closing the bus tie breaker. An angle setting of 15-25 degrees with
no time delay may be used.

Delayed Transfer on Residual Voltage

Residual voltage transfer involves waiting until the bus voltage drops below a predeter-
mined point before closing the alternate source breaker. This technique is the slowest
of the methods in that the open-circuit time of the bus is the greatest. By waiting until the
voltage is 33% of rated voltage, the resultant voltage across the alternate source
breaker is reduced to a maximum of 1.33 p.u. This supervision can be achieved with a
27 relay set at .33 per unit with no time delay or by adding a fixed time delay to the
closure of the alternate source.

Typical residual voltage decay is shown in Figure 12. The length of time required for the
voltage to decay depends on how quickly the stored electromechanical energy dissi-
pates. The motor’s open circuit time constant may be defined as follows:

where:
f = frequency
Xm = per unit magnetizing reactance of the motor
X2r = per unit rotor reactance at running speed
R2r = per unit rotor resistance at running speed

At a value of one time constant, the voltage will have decayed to 36.8% of its initial
value. Each successive time constant will drop the voltage and additional 36.8% until
no voltage remains. A safe value of residual voltage is considered .33 per unit per ANSI
and IEEE. Meeting that requirement requires a delay in circuit reclosure of at least one
to one and one-half time constants.

When auto-reclose of the motor feeder or auto-reclose of the utility source takes place,
the residual voltage considerations should be used. Either the motor should be discon-
nected prior to reclose by using an 81O/U relay, or the reclose should be delayed until
the voltage has decayed to .33 per unit.

When the user does not wish to reclose or transfer the motor load but wants to protect it
from being re-energized out of phase or with high residual voltage, a Basler BE1-81O/U
set at 97 to 98% of rated frequency with a time delay of 10-20 cycles will protect the
motor by detecting and underfrequency condition as the motor is decelerating and
tripping the supply breaker. The time delay will have to be shortened if high speed
reclosing is being used. The same relay can be used for automatic load shedding of
the motor at abnormally low frequencies. In both cases potential transformers must be
located between the motor supply breaker and the motor leads.

19
For synchronous motors, reclosing must not be permitted until proper resynchronization
can be performed. This means tripping the supply breaker with an undervoltage or
underfrequency relay.

Figure 12: Decay of open circuit voltage and phase angle.

SYNCHRONOUS MOTORS

Protection of the synchronous motor is similar to that of the induction machine with
additional requirement for field, loss of excitation and out of step conditions. The field
may have its own protection for loss of field or field undervoltage.

Out of step protection is applied to synchronous motors and synchronous condensers

to detect pullout resulting from excessive shaft load or too-low supply voltage. Small
synchronous machines with brush-type exciters are often protected against out of step
operation (or loss of excitation) by ac voltage devices connected in the field. No ac
voltage is present when the motor is operating synchronously.

Synchronous motors can be protected against loss of excitation by a low-set undercur-

rent relay connected to the field. This relay should have a time delay drop out. On large
synchronous motors an impedance relay is frequently applied that operates on

20
excessive var flow into the machine, indicating abnormally low field excitation. If an
undervoltage unit is part of the relay, its function should be shorted out because loss of
motor field may produce little or no voltage drop.

Operation of synchronous motors drawing reactive power from the system can result in
overheating in parts of the rotor that do not normally carry current. Some loss-of-field
relays (device 40) can detect this phenomenon.

The Power Factor Relay (device 55) can also be used to detect an out of step or loss of
excitation condition in a synchronous motor. When the motor loses synchronism or loss
of field it will produce watt flow out of the motor and var flow into it. A short time delay is
typical, and the relay is generally not in service until the motor is running at synchro-
nous speed.

TYPICAL PROTECTION FOR MOTORS

CASE 1 - Small Motor (100-600HP)

This example suggests the relay selection and typical settings for motors in the 100-
600HP range. This range is somewhat arbitrary. Cost and process considerations will
ultimately determine the choice of protection level. The proposed scheme shown in
Figure 13 applies to situations where the load has low inertia, the starting times are
short and a significant time margin exists between the maximum start time and the hot
stall time. The load is assumed to remain within the motor rating during normal process
conditions, allowing the use of one 51 element for locked rotor and running thermal
overload protection.

Figure 13: Typical small motor protection (100-600HP)

21
CASE 2 Medium Size Motor (600-1500HP) Single Function Relays
This example suggests the relay selection and typical settings for motors in the 600-
1500HP range. This range is somewhat arbitrary. Cost and process considerations will
ultimately determine the choice of protection level.

The proposed scheme shown in Figure 14 applies to situations where the load has
high inertia, the starting times are long and a small time margin exists between the
maximum start time and the hot stall time. The load is assumed to periodically exceed
the motor rating during normal process conditions, requiring the use of two separate 51
elements for locked rotor and running thermal overload protection. For the 51S locked
rotor protection, an Extremely Inverse characteristic will best match the hot stall time
curve. If the time dial range is insufficient, the trip time can be adjusted by raising the
tap setting to decrease the effective multiple of tap.

The 51P, running thermal overload relay must have a MPU equal to the continuous
overload limit. A time-current coordination should be performed if the protection is to be
optimized.

Figure 14: Typical medium size motor protection – Single function relays
(600-1500HP), High inertia-discrete relays.

22
CASE 2A Medium Size Motor (600-1500HP) Multifunction Relay
This example suggests the relay selection and typical settings for motors in the 600-
1500HP range. This range is somewhat arbitrary. Cost and process considerations will
ultimately determine the choice of the protection level. The functions are similar to Case
2, except that they are integrated into the BE1-851 multifunction overcurrent relay shown
in Figure 15. The 851 offers one time overcurrent and two instantaneous overcurrent for
phase, ground and negative sequence. We will also take advantage of multiple setting
groups, independent timers, and programmable time overcurrent curves. Program-
mable alarms, metering, and oscillography will help monitor the motor performance.

The 851 uses programmable BESTLogic to customize the relay operation for each
application. Two basic schemes are presented here, one for normal loads and one for
high inertia loads. Full details of the 851 programming and setting for each scheme can
be found in the 851 instruction manual.

For low inertia loads, Locked Rotor protection is covered with a “maximum start time”
logic. As shown in the Figure 15 logic diagram when the motor starts, the 62 starts
timing and the 50P is above pickup and timing. The definite time delay of the 50P is set
at the motor maximum start time with the 62 set a second or two longer. If the motor
starts successfully, the 50P will drop out before its definite timer elapses. Once the
motor is running, the 62 timer times out and blocks the logic AND gate from nuisance
tripping the motor on temporary overloads if the 50P should pick up again. If the motor
does not start successfully, the 50P will stay picked up until it times out and will trip for
locked rotor conditions.

Thermal overload protection is provided by the 51P element of the 851. The user pro-
grammable time overcurrent curve is used to simulate the I2t heating. The constants
shown in Case 2A settings table will give an approximate range of 2.5 to 25 seconds at
6 times tap for time dials 1 and 10, respectively. If a different range is required, change
the value of constant A.

The stator short circuit element (150TP) is often applied with a short time delay to over-
come asymmetrical current during fault conditions. This is not necessary in the 851
since it only measures the symmetrical current.

23
Figure 15: Typical medium size motor protection – Multifunction relays (600-1500HP),
High or low inertia-multifunction overcurrent.

24
Current unbalance (46N) detection provides rotor thermal protection. The negative
sequence (51Q) MPU setting in Amperes is approximately 5 x (max Continuous Voltage
unbalance, pu) x (Full Load Current, secondary). The time dial is set to cause tripping in
K (the assumed I22t value) seconds for I2=Full Load Current.

The programmable alarm feature of the 851 can be used to provide pre-trip alarms for
thermal overload and current unbalance.

For high inertia loads the 851 switches setting groups for locked rotor protection since
“maximum start time“ is not feasible. When the motor breaker is open, the 851 is using
setting group 0 which has the 51 set with a lower time dial to match the locked rotor
thermal limit. This is shown as the 51S curve. As shown in the Figure 15 logic diagram
when the motor starts the breaker is closed and the 50P is picked up which keeps the
relay in group 0 settings. When the motor starts successfully, the 50P will drop out and
the 851 will change to setting group 1. Setting group 1 raises the time dial on the time
overcurrent to match the running overload characteristics of the motor. This is shown as
the 51P curve. When the motor breaker is opened, the 851 returns to group 0 settings.

CASE 3 Comprehensive protection for medium and large motors (>600HP)

This protection uses dedicated microprocessor MPS200 or MPS210 relays which, in
addition to the essential 50P, 50G, 49, 46,47, 27 functions, offers undercurrent (27),
underpower (32U), low PF (55), overvoltage (59), jam protection, and 10 RTDs. There
are dual setting levels for trip and alarm for most functions. These relays track the motor
temperature accurately (thermal modelling) and offer calculated, statistical and fault
data to help the operators and maintenance personnel. See Figure 16.

Model variations allow the users to choose among integrated protection, control and
metering.

25
 Figure 16: Comprehensive protection for medium and large motors
(greater than 600HP)

CASE 3A Multifunction Protection for Medium Motors (600-1500HP)

This protection option is similar to Case 3, using the MPS100 relay. Protective functions
are the same as the MPS200 except without voltage or power functions and with only
one RTD. Phase sequence is checked upon energization and is detected in less than
500ms. The motor temperature is tracked through the thermal model, assuring correct
dynamic performance.
See Figure 17.

COMMUNICATIONS
Communications ports are standard in the MPS100, MPS200 and MPS210. Each relay
has one RS-485 with MODBUS® protocol standard. The BE1-851 relay comes standard
with one RS-485 and a front and rear RS-232. ASCII protocol is standard in the 851,
MODBUS® protocol is optional.

26
 Figure 17: Multifunction protection for medium motors.

BIBLIOGRAPHY

1) Guide for AC Motor Protection, IEEE Standard C37.96-1988.

2) Blackburn, J.L., Protective Relaying Principles and Applications, Marcel Dekker, 1987.

3) Hornak, D. L. And Zipse, D. W., Automated Bus Transfer Control for Critical Industrial Processes, IEEE
Transactions on Industry Applications, Sept/Oct 1991.

4) Motor Guide, NEMA Standard MG1-1993.

5) Nailen, R. L., Motors, Electric Power Research Institute, 1989.

6) Dymond, J. H., Stall Time, Acceleration Time, Frequency of Starting: The Myths and the Facts, IEEE
Transactions on Industry Applications, Jan/Feb 1993.

7) IEEE Guide for the Presentation of Thermal Limit Curves for Squirrel Cage Induction Machines, IEEE
Standard 620-1996.

8) Boothman, D. R., Thermal Tracking – A Rational Approach to Motor Protection, IEEE Power System
Relay Committee, Jan 1974.

27
CASE 1

ANSI Basler Model/ Basler Typical

No Qty Function Description Style Number Settings

50P 3 BE1-50/51 Detects stator BE1-50/51B-207 1.6x1LR

Instantaneous short circuits 51: H2E-Z3P-A1C0F
Or BE1-51

51P 3 BE1-50/51 Locked Rotor and BE1-50/51B-207 MPU=1.2xFLC

Inverse time thermal overload 51: H2E-Z3P-A1C0F Curve: E
Or BE1-51 TD: fit below max. safe
stall time with 2-5s
margin above start
current

51N 1 BE1-50/51 Stator ground faults BE1-50/51B-207 MPU=0.5A

Inverse time 51: H2E-Z3P-A1C0F Curve: E
Or BE1-51 TD: 0.1s @ 4xFLC
Must coordinate
against upstream 51N
relay

50N 1 BE1-50/51 Stator ground faults BE1-50/51B-207 MPU=4xFLC

Instantaneous (Residual connection)
Or BE1-51

50G 1 BE1-50/51 Stator ground faults BE1-50/51B-207 MPU=0.5A

Instantaneous (Alternate to 50/51N) Consider 310 from
Or BE1-50 (Toroidal CT) cable capacitance
before setting to max.
sensitivity

27 1 BE1-27 System undervoltage BE1-27: MPU=0.8xVnom.

H3E-E1J-B0H0F Delay: 1-10s
Consider slow clearing
system faults.

NOTE: Quantities correspond to single-function relays. Functions may be combined, as in 50/51 relay.

28
CASE 2

ANSI Basler Model/

No Qty Function Description Basler Style Number Typical Settings

150P 3 BE1-50/51 Detects stator BE1-50/51B-207 1.6x1LR

Instantaneous short circuits 51: H2E-Z3P-A1C0F
1 Or BE1-51

50P 1 BE1-50/51 Cuts out 51R when BE1-50/51B-207 0.85x1LR (at lowest
Instantaneous the motor reaches voltage)
about 50% speed

51S 1 BE1-50/51 Locked rotor BE1-50/51B-207 MPU>=1.2xFLC

Inverse time Curve: E
TD: fit below max.
safe stall time and
above start current

51P 3 BE1-50/51 Running thermal BE1-50/51B-207 MPU=1.2xFLC

Inverse time overload 51: H2E-Z3P-A1C0F Curve: E or 1
1 Or BE1-51 protection TD: below motor limit,
allow for temporary
process overloads.
Relay must have
integrating reset.

51N 1 BE1-50/51 Stator ground BE1-50/51B-207 MPU=0.5A

Inverse time faults 51: H2E-Z3P-A1C0F Curve: E
Or BE1-51 TD: 0.1s @ 4xFLC
Must coordinate
against upstream 51N
relay

50N 1 BE1-50/51 Stator ground faults BE1-50/51B-207 MPU=4xFLC

Instantaneous (Residual 51: H2E-Z3P-A1C0F
Or BE1-51 connection)

50G 1 BE1-50/51 Stator ground faults BE1-50/51B-207 MPU=0.5A Consider

Instantaneous (Alternate to 51: H2E-Z3P-A1C0F 310 from cable capaci-
Or BE1-51 50/51G) tance before setting
(Toroidal CT) to max. sensitivity

27 1 BE1-47N System BE1-47N: MPU=0.8xVnom.

undervoltage E3F-D1P-D3N0F Delay:1s-10s
Consider slow clearing

47 1 BE1-47N Phase rotation, BE1-47N: Trip MPU=5% when

voltage unbalance E3F-D1P-D3N0F connected to motor
terminals; otherwise,
check system config-
uration. Time delay:
depends on system
configuration and
timing curve selected.

NOTE: Quantities correspond to single-function relays. Functions may be combined, as in 50/51 relay.

29
CASE 2A LOW INERTIA

ANSI Basler Model/ Basler

No Qty Function Description Style No Typical Settings

150P 3* BE1-851 Detects stator BE1-851 1.6x1LR

Instantaneous short circuits H5N2S10
150TP

50P 3* BE1-851 Detects starting BE1-851 1.3x1FL

Instantaneous condition for Max. H5N2S10
50TP Start Time

51P 3* BE1-851 Running thermal BE1-851 MPU=1.2xFLC

Inverse time overload protection H5N2S10 Curve: PR
51P N=2, C=1, K=.028,
B=0, R=30, A=90
TD: below motor limit,
allow for temporary
process overloads.
Product AD > Motor
thermal time constant

51N 1* BE1-851 Stator ground faults BE1-851 MPU=0.5A

Inverse time (Residual Connection) H5N2S10 Curve: E
51N TD: 0.1s @ 4xFLC
Must coordinate
against upstream 51N
relay

50N 1* BE1-851 Stator ground faults BE1-851 MPU=4xFLC

Instantaneous (Residual connection) H3N2S10
150TN

50G (1)* BE1-851 Stator ground faults BE1-851 MPU=0.25

50TN (Alternate to 50/51N) H3N2S10 (use 1A input CT for
(Toroidal CT) neutral)

46N 1* BE1-851 Current Unbalance BE1-851 12 MPU=1.25A for 5%

51Q, 50Q, 150Q H5N2S10 voltage unbalance
Reset factor:30

27 1 BE1-47N System undervoltage BE1-47N MPU=0.8xVnom.

E3F-E1P- Delay: 1s-10s
D3N0F Consider slow clearing
system faults.

47 1 BE1-47N Phase rotation, open BE1-47N MPU=10% 3-5 sec.

phase E3F-E1P Check load
D3N0F configuration

NOTE: *All functions contained in one 851 relay.

30
CASE 2A HIGH INERTIA

ANSI Basler Model/ Description Basler

No Qty Function Style No. Typical Settings

150P 3* BE1-851 Detects stator BE1-851 1.6x1LR

Instantaneous short circuits H5N2S10
150TP

50P 3* BE1-851 Cuts out the 51S when BE1-851 0.85x1LR (at lowest
Instantaneous the motor reaches about H5N2S10 voltage)
50TP 50% speed

51S 3* BE1-851 Locked rotor BE1-851 MPU>=1.2xFLC

Inverse time H5N2S10 Curve: E
51P TD: fit below max.
safe stall time and
above start current

51P 3* BE1-851 Running thermal BE1-851 MPU=1.2xFLC

Inverse time overload protection H5N2S10 Curve: PR
51P N=2, C=1, K=.028,
B=0, R=30, A=90
TD: below motor limit,
allow for temporary
process overloads.
Product AD< Motor
Thermal Time
Constant. This
function is disabled
during start (group
switching).

51N 1* BE1-851 Stator ground faults BE1-851 MPU=0.5A

Inverse time (Residual Connection) H5N2S10 Curve: E
51N TD: 0.1s @ 4xFLC
Must coordinate
against upstream 51N
relay

50N 1* BE1-851 Stator ground faults BE1-851 MPU=4xFLC

Instantaneous (Residual connection) H5N2S10
150TN

50G (1)* BE1-851 Stator ground faults BE1-851 MPU=0.25

50TN (Alternate to 50/51N) H3N2S10 (use 1A input CT for
(Toroidal CT) neutral)

46N 1* BE1-851 Current Unbalance BE1-851 12 MPU=1.25A for 5%

51Q, 50Q, 150Q H5N2S10 voltage unbalance
Reset factor=30

27 1 BE1-47N System undervoltage BE1-47N MPU=0.8xVnom.

E3F-E1P- Delay: 1s-10s
D3N0F Consider slow clearing
system faults.

47 1 BE1-47N Phase rotation, open BE1-47N MPU=10% 3-5 sec.

phase E3F-E1P- Check load
D3N0F configuration

NOTE: *All functions contained in one 851 relay.

31
CASE 3

ANSI Basler Model/

No Qty. Function Description Basler Style No. Typical Settings

150T 1 MPS200/210 Stator short circuits MPS210-C2V1 Consult Instruction

50T Jam condition manual and GUI for
49 Thermal overload default settings and
46 Current unbalance available template
50TN Ground fault files.
37 Undercurrent
32U Underpower
27 Undervoltage
59 Overvoltage
47 Phase Loss/Reversal

87 1 BE1-87G Percentage Restraint BE1-87G: Tap=.4A

Differential G1E-A1J-A0C0F Set higher when using
low quantity CTs

87 3 BE1-50/51 Self balancing BE1-50/51B-207 .5A

Instantaneous differential

12 1 Customer Speed switch For high inertial LR

supplied protection
25-50% speed

81 1 BE1-81O/U Underfrequency BE1-81O/U: 97% of rated

Loss of Supply T3E-E1J-A6S0F frequency 10-20 cycles

CASE 3A

ANSI Basler Model/ Basler

No Qty. Function Description Style No. Typical Settings

150T 1 MPS100 Stator short circuits MPS100-51V1 Consult Instruction

50T Jam condition Manual and GUI for
49 Thermal overload default settings and
46 Current unbalance available template
50TN Ground fault files.
37 Undercurrent

32
33