02 Thermal Motor Protection Function

Protection
SIPROTEC
Thermal Motor Protection
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Agenda
General introduction thermal model

Thermal model in detail
Stator overload
Motor starting time supervision
Thermal rotor model for restart inhibit function
Thermal rotor model for negative sequence consideration
General setting recommendations
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Page 2 4-Jan-16 Dr. Herrmann / EM DG PRO LM PR
Thermal modeling of a motor?
Ambient
Thermal model becomes
C,2 C,1 Rth,1
very complicate Simplification is necessary
Hous-
ing
Differential equation higher
order One body model
Rth,2
C,4
Parameters are not given by
Rth,4
Fe losses Fe Rotor the motor manufacturer (description via differential
equation first order)
Rth,3
Rotor losses Rth thermal resistance
Cu Cu losses
C thermal capacitance
C,3
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Siemens approach
Consideration of thermal behavior in different functions
Running motor
Thermal model for stator (load current)
Thermal model for the rotor or definite time stages (I2 current)
Start or restart of the motor

Starting time supervision (I2 t curve)
Thermal model of motor (rotor) restarting (IStarting current)
General
Temperature supervision via RTD sensors
Note: Different motor protection suppliers have different approaches (main reason: technical history)

Discussion of the realization in detail
Thermal Overheating of the Stator

during continuous operation
Thermal Overheating of the Rotor

during start (too long, locked rotor)
during too frequent starts
during a negative sequence current
loss of phase
unsymmetrical voltage
Thermal overheating of bearings
Thermal overheating of plant on unloaded drives

Page 5
Stator Overload
Thermal overload impact (general)
Ppl = Relc I2 Ppl: power loss (active power), Relc: electrical resistance, I: current
PCV
Ppl
Temperature rise if Ploss > PConvection Overheating

High temperatures lead to a stress of insulating material and reduces the
lifetime / loss insulating ability (breakdown caused by temperature )
Page 6
Thermal modeling
d( 0 ) - (a - 0 ) d
I 2 = C th + I 2 R th = R th C th + - (a - 0 )
dt R th dt
Assumption I2max * Rth leads to max
d
I 2p.u. = th+ - a
dt
with the following scaling
I I a - 0 a - 0
I p.u. = = = = 2 th = R th C th U = = 2
I max k I N,M max k N max k N
Actual motor temperature
0 Reference temperature ( 40C) Solution of (
(t) = I 2
p.u. + a t =0 ) t

1 e th + t =0
a Ambient temperature
differential equation

2

2

1 I I
1 preload
2 IN,M rated motor current (NEMA: FLA)
2
k I N,M k I N, M N temperature at rated current
Calculation of the trip time ((t) =1) t = th ln k factor describes the maximum
1 I 1 a,measured 0
2 permissible load current (k =1.1)

2 + 2 1 th thermal time constant

k I N,M k N
Temperature rise after load current increasing
(Ipreload = 0)
(t), (I/IN,M)2
(I/k I N,M ) 2 Thermal

t = th ln memory
(I/k I N,M ) 2 1
100% tripping threshold
k2
IN,M rated motor current excess temperature (t)
(full load current, FLA)
k permissible overload factor
th thermal time constant
tTrip
th t

Stator Overload
Influence of the ambient temperature
Model: I2

Influence of ambient temperature on reference temperature:
C R U ref = Environment 40C = RTD 40C
ref
(t), (I/IN,M)2
Environment < 40C
100% Tripping
k2 Shift of
Temperature tripping threshold
Environment > 40C
tA th t

Page 9 January 2015 Energy Automation Products
Stator Overload
Tripping time at different overload conditions
Relation between e-function and tripping characteristic

22 = 4 N
( I )2
IN

1,52 = 2,25 N
Calculation:
100% 1,12 (1,21)
tripping threshold x% 12 (1)

1,12 = 1,21 N = tripping temperature A (100%)

1 = N = 0,83 A (83%) x = 83%
= N (1 - e -t/T) At the rated current the thermal

memory has reached a level of
I t
IN
tripping characteristic ttrip = f (I/ Imax)
2 (k = 1,1) Tripping characteristic is always inverse
1,5
1,1
1
ttrip

Stator Overload
Behaviour of thermal model with preload
100% Preload := Motor Nominal Current (FLA)
I2
tripping threshold
(K N)2
100%
1 I 2 1 I
2

80%
preload

k I N,M k I N, M
2 2
60% t = th ln

2
1 I

k 2
I 1
N,M
ttrip1 ttrip2 ttrip3

Page 11
Stator Overload
Estimation of the thermal memory level
Solution of the differential equation was: (t) = I ( 2

p.u. + a t =0 ) t

1 e th + t =0

2
Stationary conditions after 5 : 1 I 1 a 40C

(t = 5 th ) = I p.u. + a = 2
2
+
k I N,M k 2 N
1 I 2 1 40C
Thermal Memory [%] = 2 + 2 a 100%
k I k N
N, M

Examples: k= 1,1; N = 100C
Case 1: I = IN,M and a = 40C Case 2: I = IN,M and a = 55C
1 I N.M
2
1 2

I N,M
Thermal Memory [%] = 2
I
100% = 82,6 %
Thermal Memory [%] = 2 + 1 2 55C 40C 100% = 95%
1,1 1.1 I 1.1 100C
N,M N,M

Special countermeasures avoid over and under function
Using of true RMS currents (consideration of harmonics)

Evaluation of phase segregated currents (consideration of unsymmetrical load currents)
Tripping at maximum phase current (Trip := Max (L1, L2, L3))
Control of thermal model during motor start (avoid overfunction in hot motor status)1)
Strategy 1: Freeze of thermal model during motor start
Strategy 2: Limit the input current (< 2.5 IN,M) Consideration of stator winding heating
Control of thermal time constant at different load conditions
Different load current at a running motor: cooling down and heat up time constant are equal
During shut down or after trip: set cooling down time is used (e.g. no cooling via fan)
(If no value given cooling := (5-7) * heating is a good approach)
Note:1) Use strategy 1 at motors with very long starting time (e.g.. 50 s) to avoid a trip at hot starting condition.

Stator Overload
Tripping time at different conditions
Parameters:
k =1,1
Ipreload = IN,M (full load current (FLA))
th = 900 s (15 min)
N = 100C
a = 55C

Thermal Overload Rotor
Faults during start
Mechanical causes
Locked rotor (n = 0)
Inhibited start due damage or destruction of motor or drive
components or insufficient unloading of the driven machine
(accelerating torque too small) tst > tst,normal
Failure to unload the drive on the process side;
load torque > motor torque (0 < n < nN; tst > tst,normal)
Electrical causes
Interruption of a phase (n = 0)
Undervoltage (tst > tst,normal)

Starting time supervision
I
1 Current during locked rotor
U = UN 1
IStart
(Motor data) 2 Current during start up of motor
2
U < UN 2
IStart
t = t Start
I
Threshold of motor start up
IStrt>
(Setting)
IOperation = IM
tStart t
(Motor data)

Starting time measurement in a test lab
8
8
6
Multiple of rated motor current
I1 k
j
I2 k
j 4
IKL
j
0.77 0
0 2 4 6 8 10 12 14
0.1 t1 , t2 , tKL 13.5
j j j
Time in seconds
Starting current at U = Un
Starting current at U = 0,85 Un
Unrestricted Siemens AG 2015 Possible Characteristic
Lock rotor or stall time < acceleration time
I
1 Current during locked rotor
U = UN 1
2 Current during start up of motor
IStart
(Motordata)
2 Trip at:
I>Istrt> &
t>tLocked rotor &
n < nLimit
Threshold of motor start up

IStrt>
(Setting)
Limit of
locked rotor
IOperation = IM time
tLocked rotor tStart t

(Motor data)

Too frequent motor starts
Thermal stress of the rotor

Overheating of the rotor
Reduction of motor life time

Thermal Overload Rotor - Too frequent motor starts
Thermal model approach
1. Typical data of a motor

- Number of warm starts nW
- Number of cold starts nC
- Starting time tSt
- Starting current ISt
2. A thermal model 1. order is sufficient (exponential-function)
- C St
n t
3. Equations cold I : (k R I B ) = I St2 1 - e R
2

n t

( )
- w St
warm II : (k R I B ) = I St2 I B2 1 - e R + I2
2
B

4. Solutions: nC (1)
kR
nC - n W
2
St
Note: R t St (nC - n W ) (2)
IB = IN,Motor B
Temperature characteristic during repeated start
MAX
100% 400
therm.
model
Threshold of restart inhibit

K
TA
K = temperature curve at rotor cage bar upper site limit

TA = thermal model
Krun Kstop
Minimum restart inhibit time tinhibit
start up recovery start up recovery start up
0% 40
t
Thermal memory at different start conditions
Given settings:
Thermal limit of the rotor nc = 3; nw = 2
kR = 1,73
Ist = 6 IN,M
R = 355 s
tst =10 s
Threshold of Restart inhibit

(0,67)
Restart inhibit
is active Actual rotor
temperature
Starting current
10 s 7,5 s 5s

Loss of phase or unsymmetrical voltage
Thermal stress of the rotor

Overheating of the rotor due to negative sequence current
Reduction of motor life time

Influence of unsymmetrical voltage
UA
UA Positive
Sequence
UC UB
UA
UB Negative
UC UB UC Sequence
Due to the low negative sequence reactance a negative voltage

sequence leads to a high negative sequence current
1 % of U2 (5 - 6) % of I2
A thermal negative sequence model has advantages

Thermal Overload Rotor - Loss of phase or unsymmetrical voltage
Realization of protection function
The protection function calculates the negative sequence current I2 from the 3 phase currents
For evaluation of I2 there are two approaches
Definite time stages Thermal model according (I2/IN,M)2 t = K

(given a synchronous motors)
t t
Alarm
(10 30) s (10) s
Thermal characteristic
(I2/IN,M)2 t = K (2 5s)
(5 2) s
10% 15%-40% I2/IN,M

I2 perm. I2/IN,M
app. 10%

Thermal Protection via RTD elements
(stator winding, bearing temperature supervision)
Cooling unit Stator winding

(2 x RTDs) (6 x RTDs)
Bearing temperature Hot-air temperature Cold-air temperature Bearing temperature

(2 x PT100) (1 x PT100) (1 x PT100) (2 x PT100)

Insulation Design of Stator Winding
Design according temperature classes
Thermal class Maximum permissible Maximum temperature

(insulation class) continuous temperature according EN61558
A 105 C 100 C Most motors are designed

according class F and operation
E 120 C 115 C
is according class B
B 130C 120 C Data sheet: F/B
F 155 C 140C
H 180 C 165C
Practical approach: Bearing temperature trip:

Recommendation:
Measure temperature at Journal bearing: 95 C
Trip level of RTD sensor is 155 C rated load Load C Rolling-contact bearing: 110-115 C
Alarm level of RTD sensor is 140 C Alarm: Load C + 10 K
Trip : Load C + 15 K

Setting of thermal protection functions
Possible technical data (data for the stator overload)
Maximum permissible current: k =1.15 (or calculated from

maximum permissible current)
Note:
If Temperature class F/B is given then k =1.1 is always
possible
NEMA service factor (power rating in allowed V (10%) and f range)
SF=1.0 k = 1.1 (0,9 Ur *1.1 Ir 1 Ur Ir
SF= 1.15 k = 1.25 (conservative: 1.15)
Thermal time constant: 25 min

Cooling time constant: 175 min
Note: The diagram shows the thermal curve from the
copper winding (its only relevant for short-time duty)
Possible technical data (data for the starting time supervision
The technical data gives the following values:
Design of the starting time supervision between limits:

Motor starting: 5,65 I/IN and locked rotor time (hot) 9s
Setting recommendation:
IStart = 5,65 I/IN,M; Istr> = 2,5 I/IN,M
tStart = 7.5s
2
5.6
At: I = 3,9 I/IN,M t = 7,5s = 15,5 s
3.9
Tripping curve for the discussed example
Stator overload
th = 25 min
k = 1.1
Current limit: 2,5 I/IN,M
Starting time curve

Istart = 5,65 I/IN,M
Tstart = 7.5 s
Release current: 2,5 I/IN,M

Given overload curve (Example 2)
Calculation of the thermal parameters

Select a value for k (e.g. k = 1.1)
Take a current (e.g. 1,5 I/IN,M) and read out the time from
200 s
the given curve
Calculate the time constant
1
1 I 2 1 I 2

preload

k 2 I N,M k 2 I N, M
th = ln * t(I
selected )

2

1 I

k 2
I 1
N,M
Given: S.F selected k =1,1
At 200% FLA 200s (curve at lower is shown in detail)
Assumption: cold Ipreload = 0
th = 9,2 min
Compared with the previous calculation, it shows that the copper time constant
is given in the thermal limit curve. There is a risk, that during motor starting a trip at
hot condition occurs; selected thermal time constant: 20 min (S1 duty assumed)
(current limitation: 300 %FLA)

Tripping time curve (Example 2)
th = 9,2 min th = 20 min

k = 1.1 k = 1.1

Tripping curve for the discussed example 2
Stator overload
th = 20 min
k = 1.1
Current limit: 3 I/IN,M
Starting time curve

Istart = 5,6 I/IN,M
Tstart = 8 s
Release current: 3 I/IN,M
Starting values from the given starting curve:

500% FLA 7s at 100% voltage
400% FLA 10s at 80% voltage
360% FLA 12 s at 80% voltage

Restart inhibit function
Longest starting time is at lowest allowed voltage
Setting parameters:
Cold starts: 3
Warm starts: 2
3 cold starts
Starting current: 3,9 I/IN,M
Starting time: 10s
Than the motor
Restart inhibit
operates with the threshold
Internal calculated
load current
(95%)
nC 3
kR = = 1,73
nC - n W 3-2
2

R t St (nC - n W ) St = 10s *1 * 3,9 2 = 152s
B

Unbalanced load protection (negative sequence protection)
Data are available for synchronous motor Data for asynchronous motors are missing in the most cases
Setting strategy:
Follow the general setting recommendation from slide before
(it is a conservative setting strategy)
Follow the setting recommendation from vendors manual
Ask the motor manufacturer for more detailed setting values
Results from a test in the Lab:
5% U2/U1 (app. 25%I2) Motor operation 130min Winding temperature increased by12 K
50 %U2/U1 (app. 150%I2) Motor operation 60 sec Winding temperature increased by120 K
t t
20 s Alarm
(10) s
I2, perm.= 8% Thermal characteristic
(I2)2 t = 20s Alarm (I2/IN,M)2 t = 2 s
only
8s
10 s
20 s 8s
2s
1I2
3s
I2 perm. 50% 100% I2/IN,M
app. 10%
10% 25% 40%
Motor Protection
Dr. Hans-Joachim Herrmann

Principal Key Expert Protection
(Product Management)
EM DG PRO LM PR
Humboldt Street 59
91459 Nuremberg
Phone: +49 (911) 433 8266
Fax: +49 (911) 433 8301
Mobile: +49 (172) 3265902
E-mail:
hans-joachim.herrmann@siemens.com
siemens.com/answers

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02 Thermal Motor Protection Function

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Protection

Unrestricted Siemens AG 2015 siemens.com/energy-automation-products

General introduction thermal model

Unrestricted Siemens AG 2015.

Unrestricted Siemens AG 2015

Consideration of thermal behavior in different functions

Start or restart of the motor

Unrestricted Siemens AG 2015

Thermal Overheating of the Stator

Thermal Overheating of the Rotor

Thermal overheating of bearings

Thermal overheating of plant on unloaded drives

Unrestricted Siemens AG 2015

Temperature rise if Ploss > PConvection Overheating

(I/k I N,M ) 2 Thermal

th thermal time constant

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Environment < 40C

Environment > 40C

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Relation between e-function and tripping characteristic

= N (1 - e -t/T) At the rated current the thermal

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100% Preload := Motor Nominal Current (FLA)

ttrip1 ttrip2 ttrip3

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Solution of the differential equation was: (t) = I ( 2

Stationary conditions after 5 : 1 I 1 a 40C

Case 1: I = IN,M and a = 40C Case 2: I = IN,M and a = 55C

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Using of true RMS currents (consideration of harmonics)

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Threshold of motor start up

tLocked rotor tStart t

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Thermal stress of the rotor

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1. Typical data of a motor

Threshold of restart inhibit

K = temperature curve at rotor cage bar upper site limit

Threshold of Restart inhibit

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Thermal stress of the rotor

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Due to the low negative sequence reactance a negative voltage

A thermal negative sequence model has advantages

For evaluation of I2 there are two approaches

Definite time stages Thermal model according (I2/IN,M)2 t = K

10% 15%-40% I2/IN,M

Unrestricted Siemens AG 2015

Cooling unit Stator winding

Bearing temperature Hot-air temperature Cold-air temperature Bearing temperature

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Thermal class Maximum permissible Maximum temperature

A 105 C 100 C Most motors are designed

Practical approach: Bearing temperature trip:

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Maximum permissible current: k =1.15 (or calculated from

Thermal time constant: 25 min

The technical data gives the following values:

Design of the starting time supervision between limits: