July-September 2002
Issued by : EBG - Electrical Systems & Equipment, LARSEN & TOUBRO LIMITED, Powai Works, Mumbai 400 072
Industrial processes are
progressively becoming
sophisticated and the cost of
downtime is increasing. With a
large number of induction
motors in use, to control the
downtime, their protection
system plays an important role.
Hence, designing a effective
motor supply circuit and
ensuring its safety under all
opereating conditions has
paramount importance.
There is a trend towards
installing motor starters in Motor
Control Centers (MCCs) for
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Prospect / Retrospect
ease of operation and
monitoring.
Selection of control components
and provision of adequate
protection is a very important
aspect. The need for more
precise protection is
necessitated by another factor.
This has led users to size cables
economically.
When a short circuit occurs, the
Short Circuit Protective Devices
(SCPD) take a finite time to
interrupt the fault. During this
time, the current rises rapidly
and certain energy is let through
the circuit. If the let through
energy is higher than the
withstand capacity of
downstream equipment, it can
cause damage to the
downstream equipment. Thus,
achieving proper co-ordination
means matching the
characteristics of the SCPD and
the downstream equipment
including cables to ensure that
the let-through energy and peak
cut-off current do not rise above
the levels that the downstream
circuit can withstand.

Considerations for Short Circuit Protection to Starters
Protection of motor and associated
power circuit, including cables,
requires proper consideration for
different abnormlities. In the event of
an overload, the equipment is
protected by an overload relay with
certain time delay. But, in case of a
short circuit, the current needs to be
interrupted quickly for restricting the
let-through energy and consequent
damage to the downstream equipment.
This needs proper co-ordination among
the Short Circuit Protective Device
(SCPD) and downstream equipment.
TYPE OF CO-ORDINATION
IEC 60947-4-1 and IS13947 (Part4/
Section1) define two types of co-
ordination:
* Type 1
* Type 2
Type 1 co-ordination requires that,
under short-circuit conditions, the
contactor or the starter shall cause
no danger to persons or installations
and may not be suitable for further
service without repair and/or
replacement of parts. In a starter
configured with Type 1 co-ordination,
one can check all the starter
components after a fault and replace
them if necessary. But this works out
to be expensive as well as time
consuming.
Type 2 co-ordination requires that
FEATURE
under short-circuit conditions, the
contactor or starter shall cause no
danger to persons or installations and
shall be suitable for further use. Light
contact welding is accepted. Type 2
co-ordination has a major advantage.
After the fault is cleared, the user
needs just to reset the breaker or
replace the blown fuse and check for
contact welding.
Type 1 co-ordination is cheaper during
installation but Type 2 proves to be
economical in the long run.
SHORT CIRCUIT PROTECTIVE
DEVICES (SCPDs):
* Fuses
Fuses are traditionally used as
SCPDs because of their low initial
capital cost and capability to
interrupt faults faster. Fuses have
excellent current limiting
characteristics and can be applied
safely on systems having high fault
levels. Fuse is able to restrict let-
through energy at high fault levels.
At high current, the fuse element
melts (pre-arcing period) followed
by arcing which persists until the
resistance across the fuse builds
up to reduce the current to zero
(arcing period). Both these actions
take place very quickly. The
combination of high-speed
operation and high arc resistance
- Mr. D. Chatterjee
Switchgear Product Engineering
limits the peak fault current, thereby
minimising the let-through energy.
The factors to be considered while
selecting a fuse are :
n The fuse should not blow during
starting of the motor.
n The fuse should blow at a current
lower than the breaking capacity
of contactor selected.
n The fuse should blow at a current
at which overload relay, contactor
and cables are capable to handle
the let-through energy.
* MCCBs
Introduction of current limiting
MCCBs has resulted in a major
breakthrough in the reduction of let-
through energy in the system even
at higher fault level. The current
limiting MCCBs allow use of lower
size contactors and cables
compared to conventional MCCBs
resulting in cost efficient system.
In the event of a fault,these MCCBs
operate quickly, much before the
short circuit current reaches its
peak value.
The factors to be considered while
selecting an MCCB are:
n The thermal rating of MCCB should
be greater than or equal to the
motor full load current.
n The breaking capacity of the MCCB
should be greater than or equal to
the prospective fault current at its
installation point.
n The magnetic threshold setting of
the MCCB should not result in
nuisance tripping during starting of
the motor.
n Use a current limiting MCCB with
only magnetic protection (without
thermal protection) and a suitable
thermal overload relay with
matching motor characteristics.
n The thermal characteristics of
MCCB (if provided) should be such
that it falls above the overload relay
 characteristics up to the magnetic not available from a single time of this changeover, there is arcing
threshold of the MCCB. manufacturer. For e.g. if the fuse/ when the star contacts open. If delta
n The contactor should be able to MCCB manufacturer does not make contactor closes during this arcing
break currents up to the magnetic relays or contactors one has to depend period, there will be short-circuit.
threshold of the MCCB. on other makes to offer complete Hence, there is a intentional time
n The starter should be able to protection system. It is likely that the delay between opening of star
withstand let-through energy of the relay or the contactor undergoes some contactor and closing of delta
MCCB. design changes, which can affect the contactor. But during this period, there
selection combination with the fuse/ is no voltage across the motor (since
Magnetic Threshold Determination: MCCB. Thus it is very important that both star and delta contactors are
all protective equipments open). Since there is no driving torque
Typical motor starting current = 6In are available from a single to the motor, its speed starts reducing.
Maximum peak = 6In x 2.2 = 13.2In source to offer proper co- When the delta contactor closes, full
Magnetic threshold = Imag ordination. line voltage appears across the motor
Minimum value = 0.8 x Imag and it speeds up with a jerk. This kind
Peak value = 1.414 x 0.8 x Imag
* MCCBs: of star-delta staring is called as open
Therefore, for proper operation:
1.414 x 0.8 x Imag > 13.2In In current limiting MCCBs, transition. To avoid such jerks, close
Imag > 11.8In the magnetising current is transition star-delta starters are
i.e. Imag ~ 12In 12 times the nominal preferred.
(Tolerance in characteristics to be considered separately.) current. But in star-delta
starters, the current may In close transition, the changeover
For example, in star-delta starters, at shoot up to 18 times during changeover to delta is with three resistors in
starting, the starting current is reduced from star to delta. So the nominal circuit. These resistors do not allow
to 1/3rd of that with DOL starters. But, rating of the MCCB chosen should be the motor to see full line voltage as
at the instant of switching from star to 1.5 times or above the line current of well as prevent break in supply to the
delta, a high current peak I p is motor. motor, thus giving continuous driving
experienced. torque to the motor. The voltage
* CONTACTORS: coming across the motor with resistors
It may shoot up to 18 times the normal The contactor should be able to is more than that in star and less than
current depending on motor conditions. break any current upto the that in delta. This prevents jerks during
magnetic transition giving smooth changeover to
Ip = [(240 (Voltage at star) ± 415 (Voltage at delta) ] x 12In (at starting) threshold of the motor.
the MCCB. It
415
(Not for more than 2 cycles and +/- according to phase difference)
should carry Resistance calculations for close
Ip = 18In (approx.) the full load transition star-delta starters:
c u r r e n t Resistance, R = 0.4 x V2
continuously Resistance wattage,
However, this changeover takes place for the utilization category specified. (Continuous i.e. 12 starts/hr)
in a very short period of time. So, it Wr = V2
doesn’t affect the selection of the back * RELAYS: 1200 R
up fuse. However, MCCBs being peak The relay range is selected where,
sensing devices may cause nuisance according to the phase current as V = Line voltage in volts,
trip during the changeover between star the relays are connected in phase Ic = Current in amps. (in delta
to delta, if it is not properly selected. circuit. Another important factor is condition).
that the relay used should be able
SELECTION OF EQUIPMENT to withstand the let-through energy For example :
The only way to ensure Type 2 co- of the respective MCCB. Hence, in kW Rating = 150 kW
ordination, is to carry out exhaustive some cases, CT operated relays Voltage = 415 V
tests of the particular fuse & relay and are provided even in case of small Line Current = 275 A
MCCB & relay combinations with the motors. Phase Current = 159 A
contactors. While individual protection
devices may perform to a given set of CLOSE TRANSITION FOR STAR- R = 0.4 X V = 0.4 X 415 = 0.6 Ohms
characteristics, their behaviour in DELTA STARTERS: Ic 275
combination affects the way the circuit In normal star-delta schemes, first the
reacts to a fault. Selection of motor is started in star connection. Wr = V2 = (415)2 = 289.43W
equipment becomes very important When it reaches a certain speed, the 1200R 1200 x 0.6
here. Sometimes all the devices are connection is changed to delta. At the
 Close transition star-delta schematic

For further details on this subject, please contact:

EBG - Electrical Systems & Equipment, Larsen & Toubro Limited, Saki-Vihar Road, P.O. Box 8901, Powai, Mumbai 400 072
Fax: 022-858 1024 * E-mail: kotnisnd@Intebg.com

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Member Editorial Coordinators : R. S. Mahajan, Neelam D. Kotnis, EBG-ESE, Powai .