Motor Control

Starting
Disconnect Means, Controller, Starting Method

Running
Motor Protection, Wire Protection, Speed Control

Stopping
Coasting, Braking

Motor Starters
The starting mechanism that energizes the circuit to the motor There are varying devices that can be used but only two starting methods for motors.
Across the Line Reduced Voltage

Across the Line Start

Connect motor windings to line voltage.
Simplest & lowest cost way to start motor High starting torque and high starting current.

Two Types
Manual Motor Starter Magnetic Motor Starter

Reduced Voltage Starting

Apply below line voltage to motor windings during starting period then connect to line voltage once started and up to speed.
Reduced starting current & reduced starting torque. Reduce Mechanical Starting Shock

More equipment and higher cost

Reduce Inrush Current

Increase Power Quality
Reduces the in-rush current an voltage flicker on the electrical system when starting the motor. (good) Reduces the motors starting torque. (not so good)

Consideration for shutting down the load/system must be made to ensure it can be started the next time.

Reduce Mechanical Starting Shock

Applying full starting torque immediately tends to jerk the system to speed quickly.
Breakable items can be jostled. Drivelines and parts can be damaged.

Reduced torque applied to the system at starting results in a smoother soft start.
Conveyor belts Complicated drive trains with mechanical connections.

Motor Protection
Overcurrent Protection
Protect motor & circuit from very high short circuit currents.

Overload Protection
Protect motor & circuit from overload currents.

Other
Low/high voltage, phase failure, phase reversal, ground fault, bearing temperature monitors, winding temperature monitors, surge suppression, etc.

Overcurrent Protection
Must size a fuse/breaker large enough to start the motor but protect from dangerous overcurrents caused by shorts and ground faults. Generally results in too large a device to protect from overloaded conditions.

Sizing Motor Protection

Find the motors Design FLA in the NEC
1 Phase: Table 430-148 3 Phase: Table 430-150

NEC Requirements, Table 430-152

Standard Fuse Time-delay Fuse Instantaneous Trip Breaker Inverse Time Breaker 300% of FLA 175% of FLA 800% of FLA 250% of FLA

Standard Fuse

Sizing to 300% of NEC FLAthen the next highest standard size. Exception allows the next size larger when the motor will not start. Will hold 500% of rating for approximately second.

Time Delay Fuse

Size to 175% of NEC FLA, select next standard higher size. Hold 500% of their rating for up to 10 seconds. Can be sized much lower than NEC requires and provide backup overload protection.

Inverse Time Breaker

Have both thermal and magnetic features set to strip at standardized levels. Most common breaker used in the industry. Time to trip varies with amp & volt rating of breaker. Will start any motor with Locked Rotor Current below 300% of its rating.

Instantaneous Trip Breaker

Used where timedelay fuses or standard circuit breakers will not hold the starting current of the motor. NEC allows sizing up to 800% of FLA. Some have adjustable settings.

Overload Protection
Protects the motor circuit & motor from overloading conditions when the motor is running. The larger the overload, the more quickly the temperature will increase to a point of damaging the insulation on the motor windings. NEMA: motor survive a 150% overload for 2 minutes when motor is at normal operating temperature
Motor Heating Curve
Full Load Amps (%)
600 500 400 300 200 100 0

Motor Damage Area

Allowable Operation Area

0 1 2 3 4 5 6 7 8 9 10 11 12

Time (Minutes)

Overload Types
Bimetallic & Melting Alloy Overloads Heaters & or Heat cause a contactor to open Solid State Overloads Respond to current going to motor, preprogrammed for certain characteristics similar to standard overloads Electronic Overloads Microprocessor Driven monitoring of current on all phases to motor. Wide range of adjustment and calibration as well as communication

Heater Trip Characteristi

1000

Trip Time (Seconds)

100

10

1 0 200 400 600 800 1000 1200

Rated Current (%)

Bimetallic & Melting Alloy

Advantages
Responds to total heat it sees (combination of ambient & temperature rise) Simple, known technology Low cost Simple troubleshooting

Disadvantages
Located at starter and not motor (may be different temperatures Trip Variability (slow/accuracy) No additional protection other than overloads (low/high voltage, single phasing, phase unbalance, etc.)

Solid State Overloads

Advantages Ambient insensitive Wide FLA adjustment to individual motors No heaters Wide temperature range Disadvantages Set points are still extreme Generically protects while trying to prevent nuisance tripping. Many dont protect against single phasing or unbalance Cost

Electronic Overloads
Advantages
Set trip levels, trip classes and time delays Protection from all types of voltage variations including low/high, ground fault, single phasing, phase reversal and phase unbalance. Communications with controllers & PLCs

Disadvantages
Complexity Cost

Sizing Overload Devices

NEC rules allow two methods:
Calculation
Based on Motors FLA

Temperature Rating 40 Deg C 50 Deg C Will Not Start?

Service Factor up to 1.15 > 1.15 115% 115% 140% 125% 125% 140%

Mnfg. Chart in Starter Cover

Example

FLA = 22, S.F. = 1.00, AMB = 40 Deg C Whats the minimum overcurrent protection device size? Whats the minimum overload protection device size?

Step 1. NEC Full Load Amps

Find NEC Design Amps: NEC Table 430-150
3 Phase, 10 Hp, 230 Volt Amps = 28 amps

Step 2. Conductor Size

Whats the minimum conductor size? NEC 430-22: Ampacity = 125% of FLA
125% X 28 amps = 35 amps

Need a conductor with an ampacity of 35 amps.

From NEC 310-16: #8 AWG Copper

NEC does this so #8 AWG copper will be large enough for any 10 Hp motor in the future.

Step 3. Overcurrent Device

NEC Table 430-152: Standard Fuse
28 amps X 300% = 84 amps, 90 amps 50 amps 225 amps 80 amps

Time Delay Fuse

28 amps X 175% = 49 amps,

Instantaneous Breaker
28 amps X 800% = 224 amps,

Inverse Time Breaker

28 amps X 250% = 70 amps,

Step 4. Overload Device

Use the Nameplate FLA: For S.F. = 1.0, AMB = 40 deg C
22 amps X 1.15 = 25.3 amps

If this does not allow the motor to start, increase to a maximum of:
22 amps X 140% = 30.8 amps

Ambient Compensated Overloads

Standard overload devices are designed for maximum ambient temp of 104 deg F. Above: Nuisance Tripping Below: No Protection Ambient Compensated Devices have a flatter temperature response and should be used in outdoor locations.
Ambient Temperature Correction
140

Rated Current (%)

130 120 110 100 90 80 70 60 20

Non-Compensated Compensated

Standard Rating, 40 C

40

60

80

100

120

140

160

Ambient Temperature (F)

Other Protection Devices

Low/High Voltage Protection Phase Failure Protection Phase Reversal Protection Ground Fault Protection Monitors
Bearing Temperature Monitors Winding Temperature Monitors Vibration Monitors