Data Bulletin: Benefits of Thermal Magnetic Circuit Breakers
Data Bulletin: Benefits of Thermal Magnetic Circuit Breakers
Data Bulletin: Benefits of Thermal Magnetic Circuit Breakers
8998DB9901
December 1999
Seneca, SC, USA
Data Bulletin
Benefits of Thermal Magnetic Circuit Breakers
For Combination Starters in Low Voltage Motor Control Centers
Class 8998
The purpose of this bulletin is to review the use of thermal magnetic circuit
breakers (TMCBs) for motor starter applications. The specific case of a motor
control center (MCC) is considered.
Introduction
Circuit breaker
(Disconnect and
short circuit protection)
Contactor
Overload relay
(Thermal overload
protection)
M
Figure 1:
Combination Motor
Controller
1000
Class 30 OL
Class 20 OL
Class 10 OL
Time in Seconds
100
10
1
10
100
1000
Current in Amperes
Figure 2:
Since the energy conservation movement in the late 1970s improving electric
motor efficiency has been a primary goal for motor manufacturers. Energy
efficient motors employ design features that result in a higher X/R
(impedance / resistance) ratios than older standard efficiency designs.
Although these motors have lower motor full load currents (MFLC) than their
predecessors, their potentially higher motor locked rotor currents (MLRC)
and inrush characteristics can result in nuisance tripping of magnetic motor
circuit protectors (MMCPs) set to the 13 X MFLC maximum allowed in the
1996 (and 1999) NEC (Article 430-52). Trip tolerance on an MMCP is -20%/
+30% of the circuit breaker setting. A circuit breaker with a setting equivalent
to 13X MFLC may trip at 10 X MFLC and still be in tolerance.
With the advent of the Energy Policy Act of 1992, and its 1997 target
implementation date, efficiency is now a concern for the majority of industrial
applications. A new type of motor (Design E) has been defined with betterthan-normal efficiency, but even higher inrush characteristics than previous
designs. In recognition of the new design, the 1996 NEC provided for settings
of up to 17X MFLC for Design E motors.
Design E motors have not yet become common in the marketplace.
Application problems with existing energy efficient designs, however,
continue to be an issue. The 1999 NEC allows the higher 17 X MFLC setting
for current Design B energy efficient motors where lower settings are not
sufficient to start the load. In the last few years NEMA, NEC and UL
standards have all been modified to reflect higher locked rotor currents.
Changing Technology
While the application of motor starting was changing, the technology used for
motor overload protection was evolving also. Widespread use of solid state
overload relays in the 1990s has revolutionized motor protection. Features
such as current unbalance and phase loss protection are standard with
products such as the MOTOR LOGIC solid state overload relay
manufactured by Square D. Application advantages include the elimination
of thermal units (heaters) and ambient insensitivity. Because the
impedance of the overload thermal elements has been removed, units may
operate at lower temperatures or in smaller enclosures.
Time in Seconds
1000
100
Along with these new features have come new requirements. The trip
characteristic of these overload relays may differ from the original melting
alloy class equivalent.
These overload relays do not have elements in the current path and use
internal current transformers (CTs) for current sensing. Figure 3 compares a
solid state overload with the melting alloy equivalent. The variability bands
have been removed for clarity. Note the current transformer saturation point
(indicated with a black dot) on the solid state trip curve.
10
In addition, solid state overload relays may require looping for small
horsepower motors or the use of separate CTs for larger loads.
1
.5
10
Current in Amperes
100
The reduction of overall impedance can reduce the SCCR rating of the MCC
combination starter. High interrupting MMCPs or TMCBs may be required to
maintain the SCCR rating. Current limiting modules may also be available to
extend the SCCR range. This may be an important consideration in retrofits
to existing installations.
The use of thermal magnetic circuit breakers to improve the short circuit
rating or eliminate nuisance tripping associated with energy efficient motors
raises several application questions.
1000
Thermal Magnetic
Class 20 OL
100
Magnetic Only
1 hp Motor
Time in Seconds
10
Area of
Reduced
Coordination
0.10
0.01
1
10
100
1000
Current in Amperes
Figure 4:
Selection and adjustment of both MMCPs and TMCBs are based on NEC
Table 430-150 full load currents. Some branch protective devices are set in
multiples of the device CCR. This value must be calculated by dividing the
Table 430-150 MFLC by the CCR to determine the proper setting.
Proper overload trip setting is based on actual motor nameplate MFLC and
service factor. Looping for small horsepower motors or the use of separate
CTs for larger loads may require conversion to provide the correct value.
Given the large tolerance band for both the overload (+ 12.5%) and circuit
breaker (-20%/+30%) these settings are Ball Park at best.
Circuit breaker current ratings are usually the same regardless of voltage.
Motor full load currents, on the other hand, vary significantly with voltage. At
some voltages, the allowable NEC adjustment range for a given motor full
load current may not align well with the range of standard circuit breakers.
This is true especially if the allowable range is extended to 17 X MFLC. In
these cases, more than one circuit breaker may be required to cover the full
NEC allowable range.
De-rating, which is sometimes necessary as a result of ambient temperature
or altitude, will affect the overload, circuit breaker, and conductors differently.
Proper adjustment of devices in these conditions can be difficult. When
equipment is shipped from the factory, the settings are usually at the
minimum level, as the actual full load currents are not known.
Sub-contractors are not always precise in their commissioning adjustments.
It may fall to the end user to check all protection settings. Only a detailed
review by a qualified electrician, electrical inspector, or engineer can identify
improperly adjusted applications.
In the worst case scenario, the MMCP may be set to the maximum value to
complete subsystem check-out during commissioning. If the protective
device is not subsequently adjusted correctly, a significant gap in protection
may go undetected until a problem results. Many MMCP and MFLC
combinations would allow settings of 25 X MFLC and higher if set to their
maximum trip point.
The NEMA Size 1 contactor mentioned on page 5 is a good example of this.
This time, the contactor is applied in a 10 hp, 480 V, NEMA Size 1 starter with
a full load current of 14 A. An MMCP rated at 30 A is used typically (a 15 A
MMCP does not meet the 1.15 X MFLC criteria in NEC 430-110a). As
determined previously, the maximum tested contactor interrupting and
withstand current is 250 A.
The 30 A MMCP maximum setting is about 350 A (25 X MFLC), but includes
the +30% allowable UL tolerance. If the +30% allowable UL tolerance is
provided, the MMCP breaker might not trip until 455 A (32 X MFLC) (see
Figure 5 on page 7). In this case, an incorrectly adjusted MMCP could allow
the contactor to open above its tested rating in the low-level fault band
between 250 and 455 A.
1000
Thermal Magnetic
Class 20 OL
100
Magnetic Only
Time in Seconds
10 hp Motor
10
1
Area of
Improved
Coordination
0.10
0.01
10
100 250
450 1000
Current in Amperes
Figure 5:
Because most MCC applications are under 100 A, the majority of starter units
using TMCBs will not require adjustment of the magnetic trip point for short
circuit protection. In many of these applications a TMCB will provide some
degree of backup protection for improperly adjusted overload relays or
control system faults.
Although the protection crossover is shifted, TMCBs will not usually interfere
with the normal inverse time protection of a properly adjusted overload relay.
The advantages of TMCBs are particularly valuable in the following higinrush applications:
Where a transformer is switched as part of the motor circuit such as an
autotransformer starter
Where high efficiency motors are likely to be used and motor data is not
available
For use with Design E motors
Where unusual application conditions are expected such as voltage
fluctuations or extremely low power factor
With CT rated overload relays and high available fault current
TMCBs above 100 A (used in NEMA Size 4 starters and larger) usually have
an adjustable magnetic trip point similar to MMCPs. The setting is typically
adjustable from 5 to 10 X the TMCB continuous current rating (CCR). In
general, the adjustment range corresponds to values from 8 X to 14 X MFLC.
Because the instantaneous trip point is dependent on the magnetic setting,
the coordination of a TMCB and an MMCP in this range is similar.
References and Recommended
Reading
Square D Company
1990 Sandifer Blvd.
Seneca, SC 29678 USA
1-888-Square D (1-888-778-2733)
www.squared.com
1999 Square D All Rights Reserved