ELECTRIC MOTOR AND OVERCURRENT PROTECTION

Parts of a Motor Branch Circuit

A - Motor circuit conductor 125 % of current full load

B' - Motor disconnecting means

B - Motor Branch Circuit; over current protection usually 300% of full load current for
safety switch (SS) or 250% of full load current for air circuit breaker (ACB)

NOTE: These values are for general purposes motor only, values of B will depend on
type and class of motor. The range is from 150% to 300% of the full load current,
and shall in no case exceed 400% of full load current.

C - Motor Controller - rated according to motor horsepower

D - Motor Running Over current and overload protection: setting is from 115% to
125% of full load current. Value of 1.15 nd 1.25 is called service factor (SF)

1. Circuit Conductor - for the size of conductor having a maximum ampacity greater
than the calculated value to protect the conductor from burning due to overheating.
Faulty wiring is caused by the undersized conductor wire.

2. Branch Circuit Over current Protection - for protection against short circuit ground
fault which cause over current flow. It should be capable of carrying the starting
current of the motor.

3. Motor - controller ( magnetic contactor ) - used to start and stop the motor. It
includes any switch or device capable of interrupting the stalled rotor current of
motor.

4. Running Over current and Overload Protection - used to protect motor controller
and motor against excessive heating due to motor overload and failure to start.

CIRCUIT FOR MOTOR LOAD

Name plate of the motor
25 hp,220 volts, 3 phase; 3 wires
60 Hz, 0.84 power factor 90.5% efficiency

SOLUTION:

1. Solve for the current load:

1 horsepower = 746 watts

I = (load in hp x 746 w)/ (k x E x pf x n)

where:

k - 1.0 for 2 wire single phase DC

1.73 for 3 wire, 3 phase AC
2.0 for 3 wire single phase AC or DC
3.0 for 4 wires, 3 phase AC

E - voltage between the neutral and live wire or between two live wires if no neutral
line exists

I - Current in any live wire except Neutral Line

pf - power factor

N - efficiency

2. Applying the formula

I = (25 hp x 746)/(1.73 x 220 volts x .84 x 90.5%)

= 64.45 A

3. Determine the Motor feeder. The current load of a motor multiplied by 125%
(Code requirements)

4. Find the size of the conductor wire. Refer to Table, for 80.56 A, use any of the
following:

3 - 38 mm2 THW or RHW copper wire

3 - 50 mm2 TW copper wire
3 - 80 mm2 TW aluminum or copper clad alum
3 - 50 mm2 THW or RHW aluminum or copper clad aluminum

The allowable ampacities of the above wires in Table was derated by 80% to carry
the 80.56 A current load.

5. Solve for the size of conduit pipe. Refer to Table, use 50 mm diameter pipe.

6. Determine the size or rating of the over current protection. The Code provides
"The maximum over current protection for a single motor or a combination of
motors should be, 250% of the ampacity of the largest motor plus the sum of the
full load current of the other motors.

Therefore:
64.45 A x 250% = 161.15 A minimum

7. Refer to Table. Use 150 A fuse or trip breaker. It is the nearest standard rating
which does not exceed the 161.12 A current load as computed.

MATERIALS FOR MOTOR INSTALLATION:

1. 25 hp Induction motor 230 volts, 3 phase, 1800 rpm, 60 Hz at 40 degree

temperature rise

2. Magnetic thermal overload control with contractors.

3. Service entrance cap 50 mm with locknut

4. 38 mm2 THW or RHW copper wire.

5. 50 mm2 diameter IMT or RSC conduit pipe

6. Conduit clamp with screw, 50 mm conduit pipe

7. TPST safety switch or circuit breaker 150 or 250 volts

The quantity of materials depends upon the area and choice of the designing
Engineer

CALCULATION PROCEDURES IN FINDING THE SIZE OF FEEDER AND THE

OVERLOAD CURRENT PROTECTION FOR A GROUP OF MOTORS

Four 3 - phase motor 220 volts squirrel cage induction motor designed for 40 degree
Celsius temperature rise at 1800 rpm, 60 Hz

SOLUTION:
1. Determine the main feeder of the motors. Apply 25% of the biggest motor current
load plus the sum of the other motors.

(45 x 1.25) + 39 + 29 +21

= 145.25 A

2. Refer to Table. For the 145.25 A current load use any of the following conductor
wires:

3 - 80 mm2 THW or RHW copper wire

3 - 100 mm2 TW copper wire
3- 125 mm2 THW or RHW aluminum or copper clad aluminum
3 - 150 mm2 TW clad aluminum

3. Determine the main over current protection. The National Electrical Code
provides that:

" The protection rating or setting of a motor shall be 250 % percent (maximum) of
the full load current of the biggest motor being served plus the sum of the full load
current of the other motors."

(45 x 125%) x (250% +39 + 29 + 21)

140.625 + 89 = 229.625 A (maximum)

4. Refer to Table. Select a fuse or trip breaker that is nearest to standard rating that
will not exceed 229.62 A. Use 200 A.

OVERLOAD PROTECTION
Overcurrents
An overcurrent exists when the normal load current for a circuit is exceeded. It can
be in the form of an overload or short-circuit. When applied to motor circuits an
overload is any current, flowing within the normal circuit path, that is higher than
the motors normal full load amperes (F.L.A.). A short-circuit is an overcurrent which
greatly exceeds the normal full load current of the circuit. Also, as its name infers, a
short-circuit leaves the normal current carrying path of the circuit and takes a short
cut around the load and back to the power source. Motors can be damaged by both
types of currents.Single-phasing, overworking and locked rotor conditions are
just a few of the situations that can be protected against with the careful choice of
protective devices. If left unprotected, motors will continue to operate even under
abnormal conditions. The excessive current causes the motor to overheat, which in
turn causes the motor winding insulation to deteriorate and ultimately fail. Good
motor overload protection can greatly extend the useful life of a motor. Because of a
motors characteristics, many common overcurrent devices actually offer limited or
no protection.
Motor Starting Currents

When an AC motor is energized, a high inrush current occurs. Typically, during the
initial half cycle, the inrush current is often higher than 20 times the normal full load
current. After the first halfcycle the motor begins to rotate and the starting current
subsides to 4 to 8 times the normal current for several seconds. As a motor reaches
running speed, the current subsides to its normal running level. Typical motor
starting characteristics are shown in Curve 1.

Because of this inrush, motors require special overload protective devices that can
withstand the temporary overloads associated with starting currents and yet protect
the motor from sustained overloads. There are four major types. Each offers varying
degrees of protection.

Fast Acting Fuses

To offer overload protection, a protective device, depending on its application and
the motors service factor (S.F.), should be sized at 115% or less of motor F.L.A. for
1.0 S.F. or 125% or less of motor F.L.A. for 1.15 or greater S.F. However, as shown in
Curve 2, when fast-acting, non-time-delay fuses are sized to the recommended level
the motors inrush will cause nuisance openings.
 A fast-acting, non-time-delay
fuse sized at 300% will allow the motor to start but sacrifices the overload
protection of the motor. As shown by Curve 3 below, a sustained overload will
damage the motor before the fuse can open.