IIEE Foundation
Center for Training, Education and Research
2003 July 7-11, IIEE Training Center, 4/F IIEE Bldg. Cubao, Quezon City, Philippines
Module #4
Circuit Protection
1
Overview
• Common causes of motor failure
• IEC Standard Definition
• Motor protection solutions
– Extending motor life
• Smart Motor Protection
• Coordinating short circuit & overload protection (optional)
2
Motor and Machine Requirements
• Optimize production
– Avoid failures
– Minimize
downtime
• Minimize repair costs
– Motors
– Mechanical Parts
2 / Moprot_e.ppt / Feb. 1998 / P. Wildi
3
What causes a motor to fail ?
High Ambient
Temperature
Rotor Damage 9% Overload
5% Condition
30%
Bearing Damage
13%
Ageing
10%
Single Phasing
14%
Moiture & Dust
19%
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4
Fewer Costly Motor Replacements
Squirrel cage induction motor
• Rotor (rotating part)
• Stator (stationary part)
• Fan
• Windings
Stator Rotor
Cost of Downtime vs.. Dollars
Downtime
Time
5
What causes a motor to fail ?
• Heat
• Aging
• Humidity and dirt
• Mechanical
breakdown ,
vibration
3 / Moprot_e.ppt / Feb. 1998 / P. Wildi
6
Sources of Heat in Motors
• Windings
(impedance)
• Bearings (friction)
7
Heat from Windings
• Directly proportional to
load
• Windings represent
resistance
• As current increases
heat doubles as the
square of the current
8
Excessive Load
• Heat is directly correlated
to load
• Loading is a function of
– voltage
– load being driven
• Brown outs / low voltage
condition
9
High Inertia Load
• The motor takes an
abnormally long time to
accelerate.
10
High Ambient Temperature
• The ambient temperature
is high which make heat
inside the motor above
normal temperature.
• The motor may not be
able to use with big load
or long accelerating
starting time.
11
Locked Rotor Damage
Windings damaged
by excessive locked
rotor current
Note: Locked Rotor currents
can range from 6 to 10 times
the motor full load current
12
Voltage Considerations
• Overvoltage (surges)
• Undervoltage
• Voltage unbalance
13
Overvoltage
• Overvoltage causes insulation to breakdown
prematurely
• When insulation breaks down…
– short circuits can occur
– the potential for ground faults exists
14
Overvoltage Damage
Damage caused by
voltage surges
15
Undervoltage
• Undervoltage causes the motor to work harder –
– As voltage decreases current increases
16
Overcurrent Damage
Damage caused by
excessive current
17
Voltage Unbalance
5% 25%
5% Voltage Unbalance 25% Heat Increase
Result is damage to windings due to increased current
in corresponding unbalanced leg
18
Result of Unbalanced Voltage
Motor winding damaged as
result of unbalanced
voltage
19
Phase Loss
• Caused by blown fuse
or open circuit
• Leading cause of motor
failure
• Current increases in
remaining “phase”
20
Effect on Current
1.8
1.6
1.4
1.2
% Full
1 Normal
Load
0.8
Current Phase Loss
0.6
0.4
0.2
0
Phase A Phase B Phase C
Graph showing effect on full load current upon phase loss
21
Effect on Motor
Motor winding damage
due to phase loss
22
Other Contributing Factors
• Dirt ,contamination and moisture
• Poor ventilation
• Condensation
• Misapplication
23
Moisture and Contamination
• Moisture can get into the
motor due to condensation
and leakage.
• Causing premature failure
of insulation and bearing.
• Overload relay can not
protect this problem.
24
Poor Ventilation
• The motor can not get
cool air to take away
heat.
• Overload relay can not
detect this problem.
25
How to Extend Motor Life
• Detect and protect before damage occurs
• Model motor current and trip before motor winding
temperature exceeds rating
• Use protection that best fits your needs
26
Protection methods
A
Monitoring motor current
– Modeling motor temperature rise
Monitoring winding temperature
– Temperature sensors
– Temperature relays
4 / Moprot_e.ppt / Feb. 1998 / P. Wildi
27
• Overload relay:
– designation and current settings
– rated frequency, when necessary
– time-current characteristics, when necessary;
– trip class
– time, in seconds,
– number of poles;
– nature of the relay: thermal, magnetic or solid state.
28
Basic Overload Protection
• Overcurrent protection
when motor is drawing too
much current over a
specific period of time.
• Then overload device cuts
power to the motor
• Based on thermal model
of motor
• Phase loss/sensitivity
30
Basic Overload Protection
• Normal state [Link] of
O/L is normally closed.
• When O/L detect overload
condition, aux. sw will
change state to be opened.
• Then there is no supply to
the motor.
31
Basic Overload Protection
• When we start motor
by DOL, inrush current
is 6-8 time of full load
current.
• Overload relay need
to have a time delay at
start up period to
protect nuisance
tripping.
32
Overload Relay Solutions
Bimetal
Bimetallic O/L Eutectic Alloy
Solid-state
33
Traditional Thermal Overload Relay
• Let current run through
heater element to generate
the heat.
• If current is exceed setting
value, heater element will
create mechanical move to
trip it out
34
Eutectic Alloy
• Heat causes eutectic alloy to
change from solid to liquid
• Non-adjustable (discrete heater
elements)
• Phase loss response
proportional to current
35
Heater Element
• A heater elements is consisting of
– a heater coil
– a tube with a eutectic alloy
– a ratchet wheel
36
Eutectic Operation
• The excessive current will make
eutectic alloy heats up and melts.
• Then ratchet wheel can be spin freely
and open the overload relay ‘s
contact.
37
Eutectic Operation
EUTECTIC ALLOY
POWER
POWER HEATER CIRCUIT
CIRCUIT
RATCHET PAWL
PIVOT TO
STARTER
TO COIL
STARTER
COIL
CONTACT CONTROL
ACTUATOR CIRCUIT
CONTROL
CIRCUIT
Reset Position Tripped Position
38
Eutectic Alloy Overload Relay
39
Heater Element Selection
Class 10 : Type J
Class 20 : Type W
Class 20 : Type WL
For Type J and W Heater Elements, the rating of the
relay in amperes at +40C (+104F) is 115%of the “Full
Load Amperes”
For Type WL Heater Elements, the rating is 120% of the
“Full Load Amperes”
40
Bimetal Operation
• Heat causes bimetal
to deflect
• Adjustment range 1.5:1
• Phase loss sensitivity required
• 15% setting accuracy
• Manual/automatic reset
41
Bimetal Operation
• The current will go to heater element
which is a bimetallic strip.
• A bimetallic strip is made of
dissimilar metals.
• When there is overload, a bimetallic
strip will expand at different rates.
• Resulting in a deflection or
mechanical motion.
42
Bimetal Mechanism
Normal State Overload Condition
43
Phase Loss Differential Mechanism
Balanced Overload Unbalanced Overload
44
Bimetallic Overload Relay
• Once the trip is occurred,
the relay can be reset by
pressing the reset button.
• Automatic reset is available
also.
45
IEC Bimetallic Overload Relay
• Ambient temperature
compensated
• Isolated alarm contact
• Single phase sensitive
• Visible trip indication
• Manual/automatic reset
46
Applying Traditional OLRs
Bimetal Eutectic alloy
• Normal application • Normal application
(Overcurrent protection) (Overcurrent protection)
• Limited phase loss • Limited phase loss
protection protection
• Ambient temperature • Inherent adjustment
compensation security
• Manual/automatic reset • Manual reset only
47
Advance Solid State Overload Relay
• New technology of
overload relay
• Using electronic circuit to
sense the current
48
Solid-state Overload Relay
Similarities
• “Thermal
protection”
• Phase loss
protection
49
Solid-state Overload Relays
• ASIC (Application
Specific Integrated
Circuit) Provides:
– Low energy
consumption
– Logic for advance
motor protection
– Thermal memory
50
Solid-state Overload Relays
• ASIC (Application
Specific Integrated
Circuit) Provides:
– Low energy
consumption
– Logic for advance
motor protection
– Thermal memory
51
Principles of Operation (I)
Block Diagram
Current Transformer Output Contacts
Current Transformer ASIC/ Logic
Current Transformer
Power Supply
52
Solid State Overload Relay
Vs
Bi-Metal Overload Relay
53
Solid-state Overload Relay
• NEMA or IEC
• Self powered
• Adjustment range 3.2:1
• Phase loss protection
• Low energy
consumption
• Ground fault protection
• Jam/stall protection
54
Phase Lost Protection
• Phase Loss Protection:
– Caused by blown fuse or open circuit
– Leading electrical cause of motor failure
– Current increases in remaining “phase”
• Traditional Overload Relays may take 40 Seconds or more to trip
• MCS-E1 Overload Relays will trip within 2..3 Seconds on a fully loaded motor
• Protects Motor From Damage Caused by Overheating of Motor Windings
30 2..3 Sec.
20 Class 20
10 Class 15
40 Sec.
Class 10
Phase Loss Trip Times
100 600 Traditional Bimetal Overload Relays
% Current
Solid-state Overload Relays
55
Low Energy Consumption
• Traditional Bimetal Overload
Relays Consume 6 Watts of
Power 6 Watts
• Solid State Overload Relays
Consume Only 150 mW of Power
• Cooler Control Panels
150 mW
• Reduces the need for
external cooling Power Consumption
Traditional Bimetal Overload Relays
Solid-state Overload Relays
56
Thank for Today
57
