I

I
I
I
nstantaneous-trip, molded-case circuit I
breakers (MCCBs) have been applied success- I
I
fully for low-voltage motor protection for I
many years. In recent years, however, the I
I
changes in motor-starting characteristics have cre- I
ated more difficult challenges for the application I
I
engineer. The major challenge is successfully start- I
ing the low-voltage motor without causing the in- I
I
stantaneous-trip breaker to falsely trip without I
exceeding equipment ratings or violating limita- I
tions in the National Electrical Code (NEC) 111. I
I
Right sizing circuit breakers for use in I
low-voltage combination motor starters is critical to I
I
the successful, reliable operation of plant and pro- I
cess facilities. If not properly applied, false tripping I
I
on motor starting and contact welding ofcontactors I
may occur. Moreover, changes in the NBC and im- I
I
proved motor efficiencies have impacted equipment I
selection and protection. The following information I
I
is intended to guide application engineers in their I
selection ofthe right breaker and its setting for more I
I
reliable motor protecrion: I
Combination motor-starter components, I
I
Circuit breaker characteristics, I
Circuit breaker and combination starter troller and a disconnecting means. The controller I
, testing, may or may not contain overload protection,
short-circuit protection, or both. Where an indi-
I
I
Motor starting characteristics, and I
Component selection using coordination ex- vidual controller is enclosed, it includes an external I
means for operating the disconnecting means 131. I
amples. I
The examples show how selecting the right Then, it defines a combination motor controller as I
a combination controller intended for motor ser- I
breaker and breaker setting can avoid false tripping I
during starting, mitigate contact welding, and vice. A combination starter is one form of a com- I
bination motor controller and is supplied as an I
provide backup protection for overload conditions. I
I
Lorraine K. Padden is with Padden Engineering, LLC, I
I
Combhution Motor-Starter Components of Katy, Texas. George D. Gregory is with Square D I
I
UL 508. the Underwriters Laboratories (UL) Stan- -- - . of Cedar Ratiias, Iowa. Both authors are Se-
ComDany
I
dard for Industrial Control Equipment, defines a nior Members ofthe IEEE. This article appeared in its I
combination controller as an open or enclosed de- oviginalfirni at the 1998 IEEE IAS Petroleum ana I
I
vice containing both a magnetic or solid-state con- Chemical Indnstry Conference. I
I
I

1077-26 lSIO0/~10.0002000IBBE IF& /ndus/ry Appb/ions Magazine Sepfember/OrioCer 2000

14a
 I
I
I
I
I current [l]. Controllers must be capable of inter-
I
I 3 rupting the motor locked-rotor current experi-
I enced during motor starting and locked rotor
I
I conditions. An inverse-time circuit breaker is al-
I lowed to serve as a controller in addition to provid-
I
I ing short-circuit protection and serving as the
I disconnecting: means; however, an instanta-
I
I neous-trip circuit breaker is not allowed to serve as
I the controller under the 1999 NEC. In the process
I
I industry, controllers are usually either magnetic or
I vacuum contactors.
I individually enclosed unit or as an individual unit
I Bach contactor size has a continuous current
I to be installed in a motor control center [3]. rating and is designed for use with a particular mo-
I Relating these definitions t o Section
I tor voltage, horsepower, and locked rotor current,
I 430-52(~)(3)of the NEC, the combination starters as defined in NEMA standard ICs 2 [4]. To accom-
1 in which an instantaneous-trip circuit breaker will modate the higher locked rotor currents of en-
I
I be used will contain at least an overload relay, a ergy-efficient motors, the 1996 NEC added an
I controller (contactor), and the circuit breaker [l}. exception to Section 430-83 to increase the horse-
I
I
A combination motor controller will be marked power rating of the controllers for NEMA Design
I with ratings of voltage and horsepower and will E motors by 130% to 140% or use controllers spe-
I generally have a short-circuit current rating. Dif-
I cifically marked for use with Design E motors ll].
I ferent horsepower and short-circuit current ratings NEMA Design E motors are not being manufac-
I may be associated with different voltages.
I tured, so plans are to remove them from NEMA
I It is helpful to understand the combination mo- MG-1. Similar concerns regarding the contactor
I tor starter components as they are outlined in the
I rating matching the locked rotor current addressed
I NEC. Fig. 430-1 of the NEC is a convenient refer- in the 1996 and 1999 NEC Section 430-83apply
I ence fl}. Fig. 1 shows a single-line diagram of a
I to energy-efficient NEMA Design B motors, but
I typical combination motor starter used in indus- no NEC requirements have been incorporated to
I try. The minimum components typically incliided
I date to increase the contactor horsepower rating for
I in a combination starter are discussed in this sec- energy-efficient motors.
I tion: overload relay, contactor, and an instanta-
I
I neous-trip circuit breaker.
I
lnstuntuneous-Trip MCCB
I The breaker serves two functions when used as indi-
I Overload Relay
cated in Fig. 1. One, it is the disconnecting means
I Motor overload protection is required to protcct
I referred to in NEC 430 Section J. Two, it is the
I
motors, motor-control apparatus, and branch-cir-
short-circuit and ground-fault protection of NEC
I cuit conductors against excessive heating (thermal
I 430 Section D. An instantaneous-trip circuit
I
protection) due to motor overloads and failure to
breaker may serve as the disconnecting means only if
I start. Overload relays are generally of three types:
I it is part of a listed combination motor controller.
bimetallic, eutectic, or static.
I NEC Section 430-1 10 requires the disconnecting
I
I means to have a continuous current rating of at least
Contactor
I 115% of the motors full-load current (FLC) El}.
I As defined in NEC 430-81(a), a controller is any
I The instantaneous-trip circuit breaker can be
switch or device normally used to start and stop a
I used as the short-circuit and ground-fault protec-
I motor by making and breaking the motor circuit
I tion only if it is adjustable and part of a listed com-
I bination motor starter. Thermal protection is
I
I
provided by other components in the circuit.
I
I
I

I
I Circuit Breaker Characteristics
I There are two basic types of MCCBs: inverse time
I and instantaneous trip. Inverse-time circuit break-
I
I ers may have either a thermal-magnetic or elec-
I tronic sensing element. The instantaneous-trip
I
I circuit breaker is essentially a thermal-magnetic
I circuit breaker with the thermal sensing element
I
I removed. This section provides a discussion of the
I operation and tripping characteristics of these two
I
I types of breakers. As a comparison, Figs. 3 and 4

a
I Pig. 1. Comnhirzation motor starter components. show the tripping characteristics of the thermal-

/E lndustry Apphlions Muguzine 5eptember/O~tober 2000

I
 I
I
I
I
I
magnetic circuit breaker and t h e instanta- I
neous-trip circuit breaker, respectively. I
I
I
Breaker Operation I
I
The thermal-magnetic breaker is made up of two I
components: a thermal sensing element and, gen- I
I
erally, an electromagnetic sensing element. The I
thermal element reacts to heat generated by the I
I
current flowing through the breaker for the in- I
verse-time characteristic. The electromagnetic ele- I
I
ment comprises the instantaneous-trip feature. I
The electromagnet used for tripping develops a I
For consistency, adjustable-trip current settings I
force that is proportional to the square of the in- I
stantaneous value of current as shown in Fig. 2. marked on the breakers and the characteristic curves I
When the force is great enough, the latch of the are plotted in RMS values. Refer to Fig. 3 , which il- I
I
opening mechanism begins to unlatch. Unlatching lustrates the RMS value of an asymmetrical current I
is completed when work done is sufficient to move waveform. (Note that motor starting current and I
I
the latch completely off of its mating surface fault current will be asymmetrical waveforms.) I
shown as distance x in Fig. 2. At relatively low cur- The RMS value of the instantaneous setting I
I
rent magnitudes, more than a single half cycle may corresponds to the maximum trip setting allowed I
be necessary to provide the needed unlatching in NEC Table 430-152 and Section 430-52 Cl]. I
I
work. At high fault current values, unlatching I
work is completed in a half cycle. Trip Tolerances I
I
Because the trip settings are in root-mean- MCCBs exhibit a band of tripping current for any I
square (RIMS)current values and the electromagnet given instantaneous-trip setting. According to UL I
489, the UL Standard for Safety for MCCBs, the I
used for tripping is proportional to the square of I
the instantaneous current values, experimentaLion trip range tolerance is as indicated in Table I [ 5 ] . A I
is required to correlate the two. The RMS values of considerably tighter degree ofprecision exists with I
I
tripping current are recorded to establish the trip electronic trip units; however, there is no industry I
settings. The RMS value is shown in Fig. 3. standard for a tolerance closer than in Table I. I
I

*
I

I -
Electromagnetic
Force
W = F*dx
ThermdMagnetic C haracteristic
The most commonly available MCCB is ther-
m a I - m a g ne t i c . A t y p i c a1 thermal - mag net i c
I
I
I
I
I
MCCB characteristic appears in Fig. 4. A ther- I
mal-magnetic circuit breakers inverse-time func- I
I
tion can provide the thermal overload protection if I
I
I
I
F = Force I
i(f) = Instantaneous Current I
1
W =Work I
I
Fig. 2. Illustrution of the force and work done by the I
electrornugnet to trip the breaker. I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Fig. 3. Asymmetricdl wuueform shouling the RMS I
I
v a l m , which corresponcls to the trip setting und Fig8 4. Time-current characteristic for U 150-A I
coordinution plot vulzies. I
arljustuhle trip thermul-mugnetic M C C B . I

/E hdustry Appbtions Mogazifle September/Ottober 2000

4a
 I
I
I
I brated and marked in RMS terms, though the sens-
I
I ing mechanism is usually an electromagnet sensing
I instantaneous current.
I
I An instantaneous-trip circuit breaker is rated in
I continuous current and volts. I t is not permitted to
I
I have a marked interrupting rating as a means of
I distinguishing i t from the listed circuit breaker in-
I
I tended for branch-circuit protection.
I The instantaneous-trip circuit breaker is Com-
I
I ponent Recognized by UL rather than Listed.
I This recognition may be indicated by the optional
I
I marking ofa backward UR symbol on the product.
I Component recognition indicates that the product
I is incomplete. The product will be completed
I
I when it is installed in Listed equipment for which
I use it has been investigated. In this case, the instan-
I
I taneous-trip circuit breaker is made complete by
I installing it in a listed combination motor starter
I
I 480 V Current Scale x 10 in compliance with NEC Section 430-52(~)(3)111.
I This NEC section requires that the combination
I Fig. 5 . Time-current characteristic for a 150-A
I have coordinated overload, short-circuit, and
I instantaneoris-trip MCC B . ground-fault protection in each conductor. Com-
I
I bination starters and combination motor-control
I
sized in accordance with NEC 430 Part C. In mo:
units used in motor-control centers are two exam-
I cases, however, it provides backup protection for a
I ples of combination motor controllers.
I
thermal overload relay (shown in the single-line in
As a component-recognized device intended for
I Fig. 1 and illustrated in the coordination plot in
I use in a combination unit, the only short-circuit
I
Fig. 10) 111. Smaller current rated thermal-mag- current rating is applied to the combination unit.
I netic MCCBs typically have fixed instanta-
I
Because incidents of instantaneous-trip circuit
neous-trip settings at about 10 to 20 times the breaker misapplication have occurred, the industry
I
I rated current, whereas the larger, current-rated has been reluctant to add interrupting ratings on
I thermal-magnetic breakers may have the adjust-
I instantaneous-trip MCCBs. However, manufac-
I able instantaneous-trip settings that typically turers may be able to provide interrupt rating in-
I range from 5 to 10 times the continuous current
I formation about these products, if needed.
I rating of the MCCB. The availability of the adjust-
I able features depends on the manufacturer.
I
I Like the instantaneous-trip breaker, the ther- Breuker und Starter Testing
I mal-magnetic breaker can be used as the discon-
I The starter components are tested separately under
I n e c t a n d as t h e s h o r t - c i r c u i t p r o t e c t i o n . various standards. The components are then assem-
I Additionally, it can provide overload protection.
I bled into a combination motor starter and tested as
I a unit. This section discusses the separate testing
I Instantaneous-Trip Characteristic
I for an instantaneous-trip circuit breaker and the as-
I The instantaneous-trip circuit breaker characteris- sembled combination motor starter.
I tic appears in Fig. 5 . The instantaneous sensing el-
I
I ement, usually an electromagnet, can be adjusted Testing of Instantaneous-Trip
I to the needed trip value. Circuit Breakers
I
I Instantaneous-trip MCCBs are available in con- Under UL 489, an instantaneous-trip circuit
I tinuous current ratings from 3 through 1200 A. breaker is required to complete overload, tempera-
I
I The instantaneous setting typically can be adjusted ture, and endurance testing identical to that which
I in fixed steps to between about 3 CO 11 times the a listed circuit breaker is subjected and with iden-
I
I continuous current rating. The settings are cali- tical performance criteria [ 5 ] . Calibration testing
I
I
I
I
I Low Seffing High Setting
I
I Thermal-magneticor electronic trip *25% t30X
I .F
I -20%
I
I Instantaneous trip t30% +30%
I
I -20% -20%

a
I

I
 I
I
I
is done on each pole of each tested sample before I
I
and after each test sequence to verify tripping I
within Table I tolerances. Dielectric withstand I
testing is also done following each test sequence. I
I
A short-circuit interrupting test is performed for I
the listed circuit breaker at the standard level, lim- I
I
ited available current. In this test, a trip coil is per- I
mitted to burn out. However, ifa trip coil burns out, I
I
a second set of samples is subjected to a repeat of the I
short-circuit test with an impedance equivalent to I
I
that of an overload relay, in which test the trip coil I
may not burn out. For three-pole circuit breakers up load relay. The circuit breaker trip setting is ad- I
justed to maximum or its mechanism is impaired I
to 800 A, rated 480 or 600 V, this test consists of I
two short circuits on each pole with 8660 A avail- to prevent its tripping during the test. I
Con~actor-OverloadTest:A magnetic or a vacuum I
able a t line-to-line voltage and a common I
three-phase short-circuit with 10,000 A available. contactor is required to break 1000% ofmaximum I
These seven short-circuit operations are followed by FLC (based on the hp and voltages in NEC Table I
I
a calibration and a dielectric withstand test. 430-150) at maximum-rated voltage and 50% I
power factor for three operations under conditions I
I
Combination Motor-Starter Tests of maximum voltage, power, and current for each I
Refer to Fig. 1 for the components. Component rating of the combination controller. For example, I
I
tests of the circuit breaker were discussed above. a size 4 contactor is used for a 50-hp motor at 230 V I
The overload relay and contactor will each be with FLC of 130 A, and for a 100-hp motor at 460 I
I
tested as a component under UL 508 131. Then, the V with a FLC of 96 A. It would be break tested at I
combination is subjected to the following tests: 1300 A (10 X 130 A) at probably 600 V. During I
I
Temperature, the test, the contactor is required to break the cir- I
Dielectric withstand, cuit without mechanical or electrical breakdown I
I
Current withstand, and without contact weld. I
Combination Short-Civcait Test: Bach combina- I
Contactor overload, I
Combination short-circuit, and tion controller is subjected to a specified short-cir- I
cuit level corresponding to its horsepower rating. I
High available short-circuit current. I
A brief description is provided for tests related These are shown in Table 11. Connection wire is I
sized to at least 125% of the FLC rating of the cur- I
to this article. For the current-withstand test and I
all short-circuit tests, a wide range of combination rent element. Four feet of wire on the supply side I
connect the unit to test station terminals, and an I
controller samples are tested to cover the possible I
combinations of overload relays, current elements, additional four feet ofwire on the load side connect I
the unit to the short-circuit point. The circuit I
and instantaneous-trip circuit breaker trip coils. I
Temperature Test: The combination controller is breaker is adjusted to its maximum setting. The I
required to carry FLC continuously and retain tem- number of short-circuit operations varies and is I
I
peratures compatible with materials and compo- shown in Table 11. I
Criteria for acceptance include the following I
nents used in the combination controller. I
Current-Withstand Test: The combination con- points: I
m The circuit breaker or contactor must clear I
troller is required to carry 600%, and then 1000%, I
of FLC without damage to any parts or connected the circuit. I
wire that would impair their function. The test is The circuit breaker must retain its integrity I
I
continued until the circuit is opened by the over- and demonstrate compliance with calibra- I
I
I
I
I
CombinationRating Short-Circuit l e v e l I
Number of Short-circuit Operations I
I
I hP 1000 A Three for one-phose I
I
Two for three-phase I
I
2 to 50 hp 5000 A Three for one-phose I
I
Two for three-phase I
F I
I
51 to 200 hp 10,000 A Two for three-phose I
I
~ ~~~~

Above 200 hp 18,000 A and greater One for Ihree-phase I

I
I
 I
I
I
I tion and dielectric-withstand testing follow- fully ratedbreakers (e.g., for a 65-kA rated MCC,
I
I ing all short-circuit operations. the breakers would be rated 65 kA).
I Other factors to consider when determining the
I The contactor and overload relay may be in-
I operative, but insulating material must re- short-circuit rating for MCCBs are discusscd in [6]
I and {7}.
I main intact such that live parts are not
I exposed and parts may not be expelled ftom
I
I the housing.
I Contacts of a contactor may weld or may dis-
I Motor-Starting Characteristics
I integrate. Over the past 10 to 20 years, motor manufacturers
I
I
Conductors may not be damaged and may have made their motors more efficient to meet gov-
I not pull out of connectors. ernment and industry needs. Certain motors man-
I
I The unit must satisfactorily complete a di- ufactured after 24 October 1997 must meet new
I electric-withstand test following short-cir- efficiency standards to comply with the Energy
I
I cuit testing. Policy Act of 1992. Design B energy-efficient mo-
I High Available Short-Circuik Current Test: This is tors comply with these standards. Energy-efficient
I
I an optional test for units to obtain a short-circuit motors areamong those with which low-power fac-
I current rating above that found in the combination tor, high starting currents can be expected. This
I
I short-circuit test. Some of the more common com- section illustrates the motor-starting current char-
I bination starter short-circuit current ratings from acteristic used by the protection engineer to set the
I
I NEMA ICs 2 are in Table 111 [4]. instantaneous-trip device.
I The high available short-circuit test procedure To gain the best protection for the motor, the
I
I is quite similar to the combination short-circuit short-circuit protection should be set or rated as
I test. Two short-circuit operations are conducted on low as possible without opening or falsely tripping
I
I each unit: an open (0)operation in which the test when thc motor starts. The starting current can be
I circuit is closed on the unit under test by a test sta- considerably higher than the running current. Pre-
I dicting the starting current is a difficult task. The
I tion device on the supply side of the unit and a
I close-open (CO) operation in which the instanta- starting current is influenced by the point on the
I voltage waveform on each phase when t h e
I neous-trip circuit breaker is closed on the test cir-
I cuit. The contactor will be closed prior to the test Contactor closes, the X/R ratio of the power system,
I and the X/R ratio of the motor. [SJ-{ lo].
I in each case using a separate supply. Criteria for ac-
I ceptance is the same as in the combination The running current of a motor is symmetrical
I short-circuit test. about the X (time) axis. The starting current is
I
I Let us clarify that a contactor is tested in an asymmetrical and has a decreasing dc component
I that is a function ofthe motor equivalent circuit.
I overload test up to 10 X FLC in which it must clear
I the circuit. For coordination purposes, be aware The classical expression of current for a resis-
I tance/inductance circuit such as a motor is given in
I that contacts may experience damage or weld un-
I der current levels above 10 X FLC. (1) Cl 11:
I
I
I
I Breaker Test versus Combindtion
I Motor-Controller Test
I
I The short-circuit test for a breaker is conducted
I with only the breaker in the test circuit connected where:
I
I with conductors on the line and load side. The i(t) = instantaneous current as a function of time
I short-circuit test for a combination starter is con- Vmaxsin(wt+a)= the applied voltage, where t is
I
I ducted with the breaker, the contactor, and the zero at the time of applying voltage
I overload connected with conductors on the line t = time
I
I and load side. The impedance of the combination a = the electrical angle at which the circuit is
I test is higher than the breaker test, resulting in closed
I
I lower fault currents flowing, even with the same = 2nf
I fault current available on the line side. A breaker
I
I may have a lower component rating than the com- -
e=tan ( W g ) = the power angle, and
I bination starter rating. Some design engineers will
I
I
specify the combination motor controllers to have
I
I
I
I
I
I
I 25 35 50 100
I

#U lfff Industry Applirotionr Mogozine m Sepfember/Otfober 2000

Ifthe switch is closed at a point on the voltage wave line terminals of the equipment. Equipment
so that the dc component is a maximum initial intended to interrupt current at other than
value, then a - 8 = -n/2as shown in Fig. 6. fault levels shall have an interrupting rating
The resultant current appears offset by the expo- at nominal circuit voltage sufficient for the
nential term as shown in Fig. 6, referred to as dc off- current that must be interrupted.
set,The amount of asymmetry is a function of the H 110-10 The overcurrent protective devices,
XIR ratio of the motor, among other things. Motor t h e total impedance, the component
manufacturers have indicated that the locked rotor short-circuit current ratings, and other char-
XIR ratio ofmotors may be as high as 9.95. As illus- acteristics of the circuit to be protected shall
trated in Fig. 6, the highest instantaneous asymmet- be selected and coordinated to permit the cir- I
I
rical RMS current could be about 175% of the cuit protective devices used to clear a fault to I
symmetrical RMS locked rotor current (LRC). do so without extensive damage to the elec- I
I
Consider the term Vmax/Zas the motor is start- trical components of the circuit 111. I
ing. The voltage Vmax may be up to 10% above According to UL 508, the phrase without ex- I
tensive damage means that the circuit is cleared I
nameplate-rated voltage and still be within an ac- I
ceptable operating range 121.Motor manufacturers without fire or shock hazard. Components must re- I
tain structural integrity such that live electrical I
have indicated that the magnitude of the motor im- I
pedance may effectively decrease during the initial parts are not exposed and will pass adielectric-with- I
stand test following a short-circuit test [3}. I
half cycle by about 10% in some cases due to the sat- I
uration of the steel. This may reduce the effective The combination motor-starter protective de- I
impedance magnitude below 1 per unit (pu). vices should also be selective with devices on the I
I
If it is recognized that LRC may vary above 6 x supply side. The selection of protective devices and I
FLC and the effective XIR ratio may be higher than the coordination of motor protection devices are dis- I
I
9.95, the dc offset may be greater than illustrated cussed in detail in [12], [13}, and E141 and will not I
in Fig. 6. For individual installations, each of the be repeated herein. This section presents coordina- I
I
factors may vary beyond those indicated here. tion examples to illustrate false tripping, contactor I
Add to this analysis the trip tolerance of +30% protection, and overload backup protection. I
I
and -20% ofthe circuit breaker, and it is clear that
a setting of 13 X FLC will not always be great
enough to avoid unwanted tripping of the circuit
breaker as shown in Fig. 6.
r 20
18
16
Trip Max. = 16.9 pu RMS

The analysis illustrated in Fig. 6 focused on 14

12
RMS current because the FLC, LRC, breaker trip 10 * Assym. LRC = 10.5 pu
8 X/R Ratio = 9.95
settings, and coordination plots are all RMS cur- 6
rent values. Recall that the electromagnet used for 4
2
tripping has a force that is proportional to the 0
square of the instantaneous current value (Fig. 2) a -2
Q -4
and is sensitive to peak values not RMS values. v
-6
This should not be an issue because the circuit -8
-in
breaker settings are calibrated and marked in terms - +-------- r---------v---Y-i
of RMS values.
In the 1999 NEC, a change was made in Section
430-52(~)(3)to allow the maximum instanta-
10 20
Time (ms)
30 40

Fig. 6. Illustration of the FLC of 1 per tinit RMS, the symmetrical LRC, and the
50 I
neous-trip circuit breaker setting for NEMA De- asymmetrical starting current with an XIR ratio of 9.95.The instantaneous-tri)
sign B energy efficient motors to be 17 X FLC. This range i s illustrated in RMS values.
change does not require a larger contactor in Sec-
tion 430-83, but the design engineer must provide
equipment that is capable of interrupting the ex-
pected fault current per Sections 110-9 and
110-10. These considerations are reviewed in more
detail below.

Coordination Discussion
The two components of coordination are protec-
tion and selectivity. The NEC addresses the pro-
tection requirements in the following sections:
110-9 Equipment intended to interrupt
current at fault levels shall have an interrupt-
ing rating sufficient for the nominal circuit I I
voltage and the current that is available at the Fig. 7. One-linediagram for a 100-hp motor showing the Combination starter.

/FEE Industry Applications Magmine September/October 2000

Ib
 ~

I
I
I
I
I
I
I but no higher than 1300% (13 X 124 A =
I
I 1612 A) for the Design B motor if demon-
I strated by an engineering evaluation.
I
I w A setting of 12 X FLC was chosen for this ex-
I ample to review possible false tripping and
I
I view interaction with other components.
I
I
I Fulse Tripping and Contactor Ruting Isszles
I Finding an appropriate circuit breaker setting that
I
I will permit starting current to flow while provid-
I ing protection for the contactor may be a challenge.
I
I An asymmetrical starting current can be several
I Fulse-Tripping Example times LRC. Recall that tlie circuit breaker settings
I
I Instantaneous-trip MCCBs can have false-tripping are marked in RMS terms. For this example, the
I problems when standard efficiency NEMA B mo- asymmetrical starting current was calculated at
I
I
tors are started due to the asymmetrical starting 1276 A, which would occur in the first half cycle.
I current and tlie tripping band on the instanta- The size 4 contactor should be tested to break up to
I neous-trip breakers, while staying within the lim-
I 10 x the maximum motor FLC, as previously dis-
I its of the NEC trip setting. Refer to Fig. 7 for the cussed; 130-A FLC and 1300-A tested breakvalue.
I simplified one-line diagram of a standard effi-
I It would seem that asetting of 1300 A would be
I ciency motor application with potential false-trip- satisfactory to permit starting current to flow
I ping problems.
I while protecting the contactor. However, the trip-
I The coordination plot in Fig. 8 was developed ping band of the circuit breaker must be consid-
I using the information in Fig. 7. The coordination
I ered. Using Table I, the tripping band for a setting
I analysis includes the following information: of 1300 A would be a range of 1040 to 1690 A. Op-
I Consider the maximum permissible setting eration at tlie low end of the band could see false
I
I foraDesignB motorof8009L ofFLC(8Xl24 tripping on starting. At the high end, the
I A = 992 A) in NEC Table 430-152. contactor might try to open above its tested break
I
I Determine whether false tripping is expected current value on a high-impedance fault, and a con-
I when starting. A typical asymmetrical start- tact weld is possible.
I ing current is assumed and calculated as fol-
I A setting of 1500 A (12 X FLC) was selected for
I lows: 1.76 X LRC (1.76 X 725 = 1276 A) in Fig. 8 to illustrate a high setting available on a typ-
I RMS terms {8]-[10], [12}. This indicates
I ical breaker without exceeding tlie NEC limit.
I that false tripping will occur with the 800% This selection still leaves a gap in which the
I setting.
I contactor is unprotected and overlaps a small range
I 1 Using NEC 430-52(~)(3) Ex 1, i t is permissi- in which the breaker could trip during motor start.
I ble to adjust the setting higher than 800%,
I An asymmetrical starting current value of 1.76
I x the LRC is a typical value used for industrial ap-
I
I plications [l1}-[13]. This assumption illustrates
I the coordination issues that arise for industrial ap-
I
I plications. In some cases, the multiplier may be
I lower or higher. W i t h tlie advent of energy-effi-
I
I cient motors, high starting current issues are in-
I creasing significantly as previously highlighted.
I
I
I Fulse-Tripping Solutions
I
I If false tripping during start still occurs when the
I instantaneous-trip setting is at tlie maximum al-
I
I lowed by tlie 1999 NEC, several options should be
I considered:
I
I w Use a thermal-magnetic MCCB or fuse in
I place of the instantaneous-trip MCCB.
I
I Fixed-trip thermal-magnetic MCCBs have
I an instantaneous-trip range higher than the
I
I instantaneous-trip MCCB, thereby allow-
I ing the motor to start. Ratings of the
I
I
contactor and other components should be
I reviewed for protection. Adjustable-trip
I thermal-magnetic breakers may provide the
I Fig. 8. Time-current coordiiaation plot for a 1 00-hp
best of both worlds, allowing a higher in-

i
motor showing the unprotected area of the contactor.

/E industry Applications Magazine Septemher/October 2000

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stantaneous setting within the NEC re- rating of 10 times the maximum motor FLC value. I
quirements while providing the maximum These are generally smaller in size than comparable I
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possible protection for other components magnetic contactors, but are more expensive. A I
such as the contactor. As the design engi- costibenefit analysis may be needed to determine I
I
neer would expect, the instantaneous-trip the contactor type. I
devices are the least expensive, fixed-trip Fig. 9 shows the protected contactor at a higher I
I
thermal-magnetic breakers are more expen- instantaneous-trip setting. A size 5 contactor and a I
sive, ancl adjustable-trip thermal-magnetic breaker with an instantaneous-trip setting of 1610 A I
I
breakers are the most expensive. are illustrated. Note the NEC permits 13 x full-load I
Use an MCCB with time-delay or damping current for the setting, which would be 1612 A. The I
I
to override starting current, although they maximum trip is 2093A (1610 X 130%).The mini- I
are not readily available. mum trip is 1288 A (1610 X 80%). I
I
Use a reduced-voltage starter, such as an For this case, the size 5 contactor is protected I
autotransformer, during starting to reduce using a trip setting of l 6 1 0 A because thecontactor I
I
the starting current. Equipment size and cost break value of 2490 A (10 times maximum motor I
may be limiting. FLC) is not exceeded. Also, the breaker should not I
trip on motor start because the minimum trip is I
For energy-efficient NEMA B motors, con- I
sider allowing the instantaneous-trip setting 1288 A, which is above the asymmetrical starting I
to be 17 x the motor FLC. Cazttion! The in- current of 1276 A. I
I
stantaneous-trip setting should not be set above the This solution satisfies the protection criteria. As I
cornbinationstarter tested value. Be aware that the a result of the high starting current, protection of I
I
contactor is not tested to interrupt current above 10 the motor is not as close as might be desired. Also, I
times tbe maximum motor FLC value. selective coordination with devices on the supply I
I
side will be more of a challenge than with a lower I
Mitigating Contactor Damage setting. However, false tripping should not occur I
I
An option to avoid applying the contactor at levels and the contactor should be protected. I
above those for which it has been tested to break is I
I
to specify a larger contactor with a higher current Backap Protection I
rating. Contactors are rated to break current at 10 The design engineer should evaluate the need for I
I
times the maximum motor FLC value. Therefore, backup protection in the overload region. First, the I
the larger contactor would be protected with a overload device is normally the only line of protec- I
tion from overloads and high impedance faults I
higher setting of the instantaneous-trip MCCB I
(within the NEC requirements). when using instantaneous-trip circuit breakers. A I
If space is a factor in upsizing the contactor, vac- failure of the overload device, overload wiring, or I
I
uum contactors should be considered. They are contactor can prevent the circuit from being iso- I
typically manufactured with full-load current rat- lated due to overload or high-impedance fault con- I
I
ings of 160,320,600, and 720 A and have a break ditions. Where backup protection is desired for I
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Fig. 9 . Time-current plot f o r a 1OO-hp motor Fig. IO. Backup protection using n thernanl- I
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showing the protected contactor. mugnetic ucGiLstable instuntuneous AICCB. I

/E hdusfry App/im/ions Magazine I Sepeptember/O[eptober 2000

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I these abnormal conditions, an inverse-time circuit as given in Table I or published by the manu-
I
I breaker or fuses should be selected. Fig. 10 shows a facturer. To avoid false tripping, the asym-
I thermal-magnetic breaker with a 100-hp motor to metrical starting current should be below the
I
I illustrate the backup protection provided in the m i n i m u m tolerances of t h e instanta-
I overload region. neous-trip set point.
I
I 4 The contactor should be tested to break
I high-impedance fault conditions it may see
I Conclusions and to withstand the motor's locked rotor
I
I H A listed combination starter meets the re- current. Any condition at or below the maxi-
I quirements of the NEC and is tested such
I mum tolerances of the set point of the breaker
I that the combination of components protect should be within the break test value of the
I the motor and are self-protecting as a system. contactor. Magnetic or vacuum contactors
I
I A system designer selecting components that have adequate break test values should
I should be aware of NEC requirements and be applied to avoid welding of contacts.
I
I
understand the ratings of the combination
I starter and its components.
I 4 T h e combination starter m u s t have a
I References
I short-circuit current rating adequate for the [l) National Electficul Code, ANSUNFPA 7 0 , 1999.
I available short-circuit current on its supply [ 2 ] Motors and Generuton,NEMA MG 1, 1998.
I [3) Indastrial Contvol Equipment, ANSIiUL 508, 1993.
I side.
I [4] Industvial CotitrolandSymmns Controllers, Contutors, and Owev-
H False tripping of instantaneous-trip circuit
I loud Relays Rated Not More Than 2000 VoltsAC ur 750 Volts
I breakers is an occasional problem when mo- DC, NEMA ICs-2, 1993.
I tors are starting. The asymmetrical starting [ 5 ) Molded-Case Circiiit Breakers, hiolded-case Switches, and Civ-
I
current causes the breaker to trip without a czit-Breaker Encloszres, ANSIiUL 489, 1996.
I
I fault condition. In some cases, the maximum 16) A.J. Smith 111, "Short-circuit ratings, labels and fault
I withstandability of molded-case and insulated case circuit
I setting allowed by the NEC is not high breakers and combination motor starters," in Cor$ Rec 1991
I enough for the starting current to flow with- IEBE Petroleim and Chemical Industy Confevena, pp. 9-18.
I [?I IEBE Recommended Practice j'& Applying Lou-Voltage Cwcztzt
I out tripping the instantaneous-trip circuit
I breaker. Inverse-time circuit breakers, fuses, Breakers Used in Industrial and Coniinevcial Power System, IEEE
I Std. 1015, 1997.
I
or reduced voltage starters may be required to
18) R.R. Burke and W.R. Finley, "Trouble shooting motor
I satisfy NEC requirements. problems," in Con$ Rec. 1993 IEEE Petuolezon and Chemical
I Contactor sizes for energy efficient NEMA
I Industry Conk, pp. 303-316.
I Design B motors may need to be sized larger, 19) R.L. Nailen, "Motor inrush current: what does it really
I if using the 1999 NEC Section 430-52(~)(3) mean?" Electrical Apparutns Mag., pp. 56-60, June 1986.
I [lo] H.L. Bradfield and D.W. Heath, "Short-circuit protection
I Exception No. 1, for 17 x FLC setting of the
of energy-efficient motors," I E E E Znd. Applicdt. Mag., vol.
I instantaneous-trip circuit breaker. Refer to
I 3, pp. 41-44, JanJFeb. 1997.
I NEC Section 430-83 for contactor sizing re- 1111 W.D. Stevenson, Jr., Eleinents of Pozuer System Analy.rzr,
I quirements for NEMA Design E motors Foiwth Edition. New York: McGraw-Hill, 1982.
I 1121 L.K. Padden and P. Pillai, "A flow-chart methodology for
I (Note Design E energy efficient motors are
I performing lowvoltage three-phase motor coordination
not being manufactured). The instanta- studies," in Con$ Rec. 1997 I E E E Petrulem ondCheniiid 111-
I
I neous-trip setting should not be set higher dutry Conk, pi]. 11 -23.
I than levels for which the combination starter [131 G . Gregory and L.K. Padden, "Application guidelines for
I instantaneous-trip circuit breakers in combination motor
I has been tested.
I 4 Coordination plots that simply show a starters,'' I E E E T p m J . Ind. AJiplicut.,vol. 34, pp. 697-704,
I J~il./Aiig.1998.
I straight line for an instantaneous-trip 114) L.K. Padden and P. Pillai, "Simplifying motor coordina-
I breaker should be modified to include the tion studies," I E E E Ind. Applicat. Nugib'.,vol. 5 , p. 38,
I
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manufacturing tolerance around the set point MarJApr. 1999.
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