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Basics_practical_operationMotor_protection.pdf

Necessity for motor protection

Approximate percentages cause of motor faults:

• overload 30%

• insulation damage 20%

infrared inspection

• phase failure 14%

• bearing damage 13%

• ageing 10%

• rotor damage 5%

• others 8%
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Basics_practical_operationMotor_protection.pdf

Necessity for motor protection

Reduction of an average motor winding life span due to
excessively high temperature.

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Basics_practical_operationMotor_protection.pdf

To guarantee fault-free operation of an electrical drive:

 Correct design:
A suitable motor has to be selected for each application.

 Professional operation:
Professional installation and regular maintenance are preconditions for
fault-free operation

 Good motor protection:

• It must not be tripped before the motor is put at risk.

• If the motor is put at risk, the protection device has to operate before
any damage occurs.

• If damage cannot be prevented, the protection device has to operate

quickly in order to restrict the extent of the damage as much as possible.
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 The 4 basic functions
General structure
L.V. Electrical Distribution

Isolation Isolation

Short-circuit protection Short-circuit protection

Overload protection

Switching Switching

Soft Variable
speed
starting control

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IEC 947-4-1 : Motor starters & contactors

The main points of the standard:

. More stringent testing on components

- Insulation impulse voltage test
- Increase in making and breaking capacity requirements
(performance and electrical durability)

. Creation of new utilization categories

- Trip classes for overload relays (normal / long starting time)
- New utilization categories for contactors
(capacitor switching, transformer switching, ....)

. Coordination of protections

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Example on Telemecanique Contactors

LC1-K LC1-D LC1-F LC1-B

CV1 CV3 integral

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TPS: giải thích sơ đồ
Example: "D" contactor

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Example
Type "D2" additions

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 Example: "F" Contactor

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Contactor

• In conformity with IEC 947-4

• Provides control of the motor with considerable

durability ( 1 to 2 millions operating cycles in AC-3
category)

• Provides cut-off of the power circuit when the

thermal overload relay trips

Absolute limit: breaking capacity.

! The contactor must not be stressed over
its breaking capacity.

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 Definitions and comments (IEC 947-1)

Rated operational voltage (Ue)

For 3-phase circuits it is expressed as the voltage between phases.

Rated operational current (Ie) depends on: rated operational voltage,

operating rate and duty, utilisation category and ambient temperature
around the device.

Rated conventional thermal current (Ith) The current which a closed

contactor can sustain for a minimum of 8 hours without its temperature
rise exceeding the limits given in the standards.

Permissible short time rating The current which a closed contactor can
sustain for a short time after a period of no load, without dangerous
overheating.

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Definitions and comments (IEC 947-1)

Rated operational power (expressed in kW) The rated power of the

standard motor which can be switched by the contactor, at the stated
operational voltage.
Rated breaking capacity This is the current value which the contactor
can break in accordance with the breaking conditions specified in the
IEC standard.
Rated making capacity This is the current value which the contactor
can make in accordance with the making conditions specified in the
IEC standard.
Electrical durability This is the average number of on-load operating
cycles which the main pole contacts can perform without maintenance.
The electrical durability depends on the utilisation category, the rated
operational current and the rated operational voltage.

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 Definitions and comments (IEC 947-1)

• Rated insulation voltage (Ui)

• Rated impulse withstand voltage (Uimp)

• On-load factor (m) m = t/T

Cycle duration (T): duration of current flow (t) + time at zero current

• Pole impedance

• Mechanical durability

• Rated control circuit voltage (Uc)

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TPS

Utilization category (IEC 947-4)

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 Utilization category (IEC 947-4)

• Utilization category AC-3 conforming to IEC 947-4 (squirrel cage motors):

- at switch-on: 6 motor In
- breaking whilst motor running: motor In I(A)
MC

• 3 requirements for the operational current:

Ie (AC-3)  I thermal BC

 1/10 of making capacity (MC)

 1/8 of breaking capacity (BC)

E(v)

Electrical durability is a usual value which corresponds to the user’s

requirement, i.e. 1 to 2 million operating cycles.

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Utilization category (IEC 947-4)

• Utilization category AC-4 conforming to IEC 947-4 (squirrel cage motors):

- at switch-on: 6 motor In
- breaking stalled motor: 6 motor In

• 3 requirements for the operational current:

le (AC-4)  I thermal
 1/12 of making capacity
 1/10 of breaking capacity

Basically this AC-4 category groups together the low power hoisting
applications.

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 Utilization category (IEC 947-4)

• Utilization category AC-2 conforming to IEC 947-4 (slip ring motors):

- at switch-on: 2.5 motor In
- breaking stalled motor: 2.5 motor In

Equipment for gantry cranes, higher power machines with prolonged

starting time.

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TPS
Application: utilization category (IEC 947-4)
a.c. applications

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TPS
Application: utilization category (IEC 947-4)
d.c. applications

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Application: characteristics LC1-D and LP1-D Contactors

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 Contactor selection guide for utilization category AC-3

Example: Asynchronous motor with P = 5.5 kW - Ue = 400 V - Ie = 11 A

? 27
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Tesys catalogue 2018 - Motor control and protection components_MKTED210011EN_reduced size A6/32

For utilisation categories AC-2 or AC-4

(1) Do not exceed the maximum number of operating cycles.
(2) For temperatures higher than 60 °C, use a maximum operating rate value
equal to 80 % of the actual value when selecting from the tables.

phụ thuộc vào tần số đóng cắt (cycles/h) và hệ số tiếp điện (tlv/tck)

Asynchronous motor with P = 5.5 kW - Ue = 400 V - Ie = 11 A - Ic = 6 x Ie = 66 A

If only maximum breaking current required ?
Depending on the maximum operating rate and the on-load factor:
Example from 150 and 15 % to 300 and 10 %  ?
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Tesys catalogue 2018 - Motor control and protection components_MKTED210011EN_reduced size A6/28

Selection according to required electrical durability, in category AC-3

Asynchronous
motor with
P = 5.5 kW
Ue = 400
Ie = 11 A

Electrical durability of LC1D12?  About 2.2 million operating cycles.

If 3 million operating cycles are required?  LC1D18
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Tesys catalogue 2018 - Motor control and protection components_MKTED210011EN_reduced size A6/34

Selection according to required electrical durability, in

categories AC-2 or AC-4

Motor with P =
5.5 kW, Ue =
400 V, Ie = 11 A
Ic = 6 x Ie = 66 A

200 000 operating cycles required  LC1D25

If 0.7 million operating cycles are required?  LC1D65A
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 For utilisation categories DC-2 to DC-5
Ie phụ thuộc
vào số cực
mắc nối tiếp
và điện áp.

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Comparison between utilisation categories

DC-2 to DC-5 DC-1

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Thermal overload relays

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 Thermal overload relays

• Conforming to IEC 947-4 specifications

• Protects the motor, line and devices

against overload

• Must allow the motor to start without

tripping

It must be protected against excessive

! current multiples

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Compact NSX motor protection

Micrologic 2.2 / 2.3 M electronic trip units

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TPS

Thermal overload relays

Protection curves (conforming to IEC 947-4)

Trip classes of a thermal relay

(conforming to IEC 947-4)

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Thermal overload relays

Trip classes of a thermal relay (conforming to IEC 947-4)

The four trip classes of a thermal relay are 10 A, 10, 20 and 30 (maximum
tripping times at 7.2 In).

Classes 10 and 10 A are the most commonly used.

Classes 20 and 30 are reserved for motors with difficult starting conditions.

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 Thermal overload relays
Trip classes (conforming to IEC 947-4)

Tripping time

Class 1.05 Ir 1.2 Ir 1.5 Ir 7.2 Ir

10 A >2h <2h < 2 min 2 < Tp  10 sec

10 >2h <2h < 4 min 4 < Tp  10 sec

20 >2h <2h < 8 min 6 < Tp  20 sec

30 >2h <2h < 12 min 9 < Tp  30 sec

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LR2-D Thermal overload relays

2 trip classes of motor overload protection

1- Balanced operation, 3-phase, from cold state.

2- Two phase operation, from cold state.
3- Balanced operation, 3-phase, after a long period at set current (hot state).

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TPS
Motor/Cable thermal overload protection
Motor overload protection Cable overload protection

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JFA_AG_11EM_Thermal_Damage_Curve_.pdf

TPS

Motor/Cable thermal overload protection

Cable overload protection Motor Thermal Damage Curve

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JFA_AG_11EM_Thermal_Damage_Curve_.pdf
TPS

Motor/Cable thermal overload protection

Motor overload protection Motor Thermal Damage Curve

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JFA_AG_11EM_Thermal_Damage_Curve_.pdf

TPS

Motor/Cable thermal overload protection

GV3 motor overload protection Motor Thermal Damage Curve

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JFA_AG_11EM_Thermal_Damage_Curve_.pdf
TPS
Motor thermal overload protection
GV3 motor overload protection Micrologic 2.2M, 2.3M

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 Short-circuit protective devices
by fuses

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Short-circuit protective devices

by circuit-breaker

Thermal-magnetic Magnetic
motor circuit-breaker circuit breaker (MA)

Contactor

Contactor
Thermal relay

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 Short-circuit protective devices

• Protection by circuit-breaker: • Protection by aM or gl fuses:

- conforming to IEC 947-2 - conforming to IEC 269-1 and

269-2
- limited I2t
- limited I2t
- limited electrodynamic
- limited electrodynamic
stress (I peak) stress (I peak)

the SC circuit-breaker must be aM fuses must be protected

protected against overloads against currents from In to
by a thermal overload relay 4 In by a thermal overload relay

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Short-circuit protective devices

Protection by circuit-breakers

• 3 requirements for breaking of a short-circuit current:

- to detect the faulty current very early

- to separate the contacts very quickly
- to limit the short-circuit current

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 Compact NSX motor protection
Micrologic 2.2 / 2.3 M electronic trip units

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Chọn lại CB bảo vệ động cơ BTL

Short-circuit protective devices

Protection by circuit-breakers

Magnetic-thermal motor circuit-breakers

GV2-M GV2-P GV3-M GV7-R

Breaking 15 to 100 kA 50 to 100 kA 35 to 100 kA 25 to 70 kA

capacity with 415 V with 415 V with 415 V with 415 V
Rated I
0.1 to 25 A 0.1 to 25 A 25 to 80 A 25 to 220 A
Thermal
protection sensitivity to phase sensitivity to phase No sensitivity to sensitivity to phase
loss, class 10 loss, class 10 phase loss, class 10 loss, class 10 and 20

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TeSys Catalogue 2022 _Motor control and protection components (MKTED210011EN)

TeSys Power_Deca, Giga and Modular Motor circuit breakers

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Short-circuit protective devices

Fuse protection

• Main characteristics:

- high breaking capacity  100 kA

- low cost
- requirements management of a
stock of spare cartridges

• Fuse cartridges with strikers:

used with a mechanism against

single phase operation, they
enable the motor to be stopped
immediately if the cartridge melts

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 Short-circuit protective devices
Fuse type

aM type fuses  Motor and transformer protection

Be designed to withstand high current peaks of a very short

duration. They must be combined with a thermal overload
relay coupled with a contactor.

gl type fuses  lighting circuit, supply line and furnace

protection

They are more widely used but whose limiting capacity is

weaker than that of aM type fuses.

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Short-circuit protective devices

Fuse protection
• Operation:
- the short-circuit current heats and melts the fuse element
- the silica smothers the electric arc by melting

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 Short-circuit protective devices
Fuse selection

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 61
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Contactor behaviour on non limited short-circuit

Repulsion of contacts

Isc current

Repulsion

I2t

Time

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 Contactor behaviour on non limited short-circuit
Repulsion of contacts

lsc current

I2t

Time

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Contactor behaviour on non limited short-circuit

Repulsion of contacts

lsc current

Contacts are welded

I2t

Time

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 Contactor behaviour on limited short-circuit
Repulsion of contacts

lsc current

Repulsion

I2t

Time

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Contactor behaviour on limited short-circuit

Repulsion of contacts

lsc current

I2t

Time

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 Contactor behaviour on limited short-circuit
Repulsion of contacts

lsc current

Contacts are
operational

I2t

Time

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 L.V. Electrical Distribution

Disconnection

Switching

Short circuit protection

Overload protection

Power Control

Motor
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What is the object of coordination?

• To provide protection for personnel and equipment whatever

levels of overcurrent are encountered (overload or short circuit).

• To reduce maintenance costs in the event of failures by

minimizing the repair time and equipment replacement costs.

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 Coordination of the protection devices
The spirit of the coordination standard IEC 947-4

• It prioritizes the protection of personnel:

- no manifestation is accepted outside the enclosures

- no fire hazard

• It takes into account equipment maintenance: limits the risks of

damage at the start concerned

• Reduction of downtime: continuity of service for increased

productivity

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What is a coordinated starter ?

This is the optimum combination of a short circuit protective

device with a contactor and an overload relay.

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 Coordination of the protection devices
Coordination and contactors

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DANGER: No coordination

In case of a short circuit ...

High risks for operators and personnel

High risks for installations (fire, ...)

All motor starter components will have to be replaced

before restarting

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 COORDINATION: 3 levels (IEC 947)

Coordination type 1 (IEC 947-4-1)

Coordination type 2 (IEC 947-4-1)

Total coordination (IEC 947- 6-2)

The coordination level of a given motor starter

depends entirely on:
- the electrical environment
- the selection of the motor starter components

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Type 1 coordination
(IEC 947-4-1)
In case of a short circuit ...

No danger to persons or installation

Contactor and / or overload relay might be damaged

Before restarting, the starter may need to be repaired

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 Type 2 coordination
IEC 947-4-1
In case of a short circuit ...

No danger to persons or installation

No damage to the starter is allowed

The risk of contactor contact welding is acceptable, provided the
contacts can be separated easily.

Settings of starter do not need to be readjusted

Electrical insulation must be retained after the incident and the motor starter must
be able to operate following the short circuit

Before restarting, a simple check is sufficient

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Total coordination
(IEC 947-6-2)
In case of a short circuit ...

No danger to persons or installation.

No damage to the starter, no contact tips welding is allowed,

electrical insulation must be maintained.

Immediate restarting without inspection of starters

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 Example: Applications in building sector

Air conditionning Type 1 Standard starter

Lifts / Escalators Type 2 High performance

starter

Toxic fume extractor fan Total coordination High performance

starter (integral)

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Example: Applications in industry

Packaging line Type 1 Standard starter

Bottling line Type 2 High performance

starter

Petrochemical continuous Total High performance

process coordination starter (integral)

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 catalogue_tesys_motor_starters_upto_150a_part1

D.O.L. starters, non-reversing, at 400/415 V, type 1 coordination

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catalogue_tesys_motor_starters_upto_150a_part1

D.O.L. starters, non-reversing, from 0.06 to 30 kW at 400/415 V, type 2 coordination

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 Motor starter structures
3-product solution: circuit-breaker, thermal overload relay, contactor
NS 100

Relay operating curve

Contactor breaking
capacity limit
Tripping time
< 10 s LC1-F
or < 20 s Relay thermal stress
or < 30 s limit (bimetal)
depending on
the class

Circuit-breaker
LT7
20- 30 ms operating curve

motor ln I start I magn.

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Motor starter structures

2-product solution: motor circuit-breaker + contactor

GV2-P
Circuit-breaker
operating curve
Contactor breaking
capacity limit
Tripping time
< 10 s

LC1-D

20- 30 ms

motor ln I start I magn.

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 GV – Motor protection

1. 3 poles from cold state

2. 2 poles from cold state
3. 3 poles from hot state
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Motor starter structures

1-product solution; control and protection devices:
integral 18, 32, 63

• continuous operation:

- these products provide the 4 basic functions in a single

product:
- isolation
- protection against overloads
- control
- protection against short-circuits

This type of device is defined in a special section of the IEC 947

standard: IEC 947-6-2 for control and protection devices

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 Operating curves
1-product solution

relay operating curve

combined and integral

18 and 32 <10 s
integral 63 < 20 s
the magnetic operating curve can be
set at 6 to 12 Ir max with 32 and 63
ratings

20 to 30 ms

motor ln I start I magn.

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