278 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. IA-9, NO.

3, MAY/JUNE 1973

A Better Approach to Motor Circuit Protection

RAYMOND 0. D. WHITT

Abstract-Over the years, various approaches including both thermal ing. Chart 430-37 is provided which outlines the number and
magnetic breakers and several types of fusible devices have been used location of overcurrent devices in various types of supply
in motor circuit protection schemes with acceptable results. Evidence systems.
reported in the trade magazines indicated that the level of protection
from these types of devices was not totally effective. For the first Motor branch circuit, short-circuit, and ground fault protec-
tion is covered in paragraph 430-D. This paragraph outlines
time, with the printing of the 1968 National Electric Code, the applica-
tion of instantaneous trip circuit breakers (without time delay) was the various types of devices that may be applied as well as the
allowed provided the pickup could be adjusted above 700 percent to a maximum setting allowed for each type device. Requirements
maximum of 1300 percent of the motor full-load ampere rating. After are given for individual motors, multispeed motors, and
extensive testing the first product complying with these requirements
was introduced to the market in 1969. Experience in motor failures multiple motors on one branch circuit. Table 430-152 con-
veniently summarizes the recommended maximum settings of
indicates that most faults occur at relatively low levels of fault current
just above lock rotor values rather than at higher levels. With rapid motor branch circuit protective devices in terms of percent of
clearing of faults in the low-level range such as can be accomplished motor full-load currents.
with the use of instantaneous trip circuit breakers, extensive damage to With the passing of the new Federal Occupational Safety
motors as well as to control equipment can be greatly reduced. By
combining low-level protection obtained with the high interrupting and Health Laws-better known as O.S.H.A.-more emphasis
capabilities of specially designed current limiters, a full range of than ever before will be placed on compliance with the NEC.
Since the Law was originally passed, it has been amended and
coordinated protection is available for both high- and low-level faults.
announced in the Federal Register dated 72-2-16 to specify
the applicable Code to be in the 1971 NEC. As of 72-3-15 all
INTRODUCTION new electrical construction work shall be in accordance with
W7, [ ITH RECENT changes in the National Electric Code the 1971 NEC.
AY [(NEC), new avenues of motor circuit protection have The Underwriters' Laboratories (UL), Inc., Standard for
been opened so that better, closer protection than ever before Safety Number UL 508 [2] covers the specific design and test
can now be achieved. requirements for industrial control equipment. This standard
This paper will briefly cover the requirements of adequate outlines the specific design and testing requirements for the
motor circuit protection, review the components used in motor components of a combination motor controller-unless specifi-
circuit protection, discuss the levels of motor circuit fault cally covered by another standard such as UL 489 for molded
currents, and present a new method of achieving a better case circuit breakers-as well as the enclosure itself.
approach to motor circuit protection. In general, the NEC outlines the minimum application re-
quirements for the protection of a motor branch circuit in
REQUIREMENTS OF ADEQUATE MOTOR CIRCUIT terms of running overload protection and short-circuit protec-
PROTECTION tion while the appropriate applicable UL Standard defines the
Article 430 of the 1971 Edition of the NEC [1] adequately design, performance, and test requirements of the components
outlines the minimum requirements for motors, motor circuits, employed. The Standard outlines the types of tests to be
and controllers. Article 430 is subdivided into several alpha- performed, the parameters of the tests, the number of test
betical subsections according to the function involved. This samples involved, and gives the levels of performance accepted.
paper will concentrate mainly oni subsections 430-C and The users of motor circuit control and protection equip-
430-D. ment have many individual application requirements and
Motor and branch-circuit running overcurren t protection is standards that they adhere to that often surpass the minimums
covered in paragraph 430-C. This section in general defines outlined in the NEC. The objects of these many individual
the meaning of overloads and proceeds to outline the various requirements that are specified by these users include: maxi-
levels of overcurrent protection that are to be provided for mum continuity of production, minimum downtime, protec-
motors having either integral overcurrent protectors or separate tion of original investment, and personnel safety. The best
overcurrent devices. Separate requirements are outlined for way to achieve all of these goals is to provide coordinated
motors over and/or under one horsepower as well as for con- motor circuit protection where each component in the system
tinuous duty, intermittent duty, manual and automatic start- performs its intended function in the proper manner and time.
Motor failures will continue to occur for a variety of reasons.
Paper TOD-72-153, approved by the Petroleum and Chemical Industry The purpose of proper motor circuit protection is to clear the
-ommittee of the IEEE Industry Applications Society for presentation motor circuit from these faults as rapidly as possible upon the
at the Industry Petroleum and Chemical Industry Technical Conference,
senver, Colo., September 18-20, 1972. Manuscript released for publi- detection of the fault thus reducing the level of damage to the
-ation December 22, 1972. minimum. This will most likely be achieved when the circuit
The author is with Westinghouse Electric Corporation, Beaver, Pa.
15009. components are properly designed and coordinated.
WHITT: MOTOR CIRCUIT PRORECTION
Coordinated protection could also include ground fault pro-
tection which is not ordinarily achieved through normal over-
load and short-circuit protection devices used in motor control
circuits. For the first time, in the 1971 NEC under paragraph
230-95, ground fault protection is required under certain
conditions on service entrance equipment. When ground fault
protection is required, the maximum pick-up setting allowed
in the Code is 1200 A. At the present, ground fault protection
is only required on the main disconnect, but a fine print note
in the Code indicates the further need for additional ground
fault protection on feeders and branch circuits to insure maxi-
mum continuity of service. With this consideration in mind,
the addition of proper ground fault protective devices to motor
branch circuits will be necessary to achieve the overall coordi-
nated protection required to satisfy both phase overload
and/or ground fault conditions.
COMPONENTS USED IN PROTECTION OF MOTOR
CONTROL CIRCUITS
Prior to the introduction of the 1968 NEC, the most popular
type of circuit breaker used in motor control circuits was the
thermal-magnetic type which, as the name implies, includes
both a thermal element designed to function on overloads and
a magnetic element designed to function on short circuits.
The thermal magnetic circuit breaker is described in the Code
as a time limit breaker. Time limit circuit breakers were applied
in line with Tables 430-152 and/or 430-153. As an example,
for squirrel-cage motors, time limit circuit breakers were
applied at a maximum of 250-percent motor full-load cur-
rent rating.
In the lower ratings of thermal magnetic breakers, the mag-
netic circuit is nonadjustable and could be in the range of 20
to 40 times the continuous rating of the breaker. With devices
of this type properly applied in accordance with the 250-
percent application rule, the magnetic trip could vary from
50 to 200 times actual motor full-load current. For smaller
motors, the percentage of magnetic trip could increase greatly
since the minimum UL listed thermal magnetic breaker is
rated IS A.
The most commonly used fuse for motor branch circuit
protection was the one time or so-called NEC fuse. One time
fuses also were applied in accordance with Tables 430-152
and 430-153 for a squirrel-cage motor as the preceeding but, at
300-percent of motor full-load current. Under specific condi-
tions, both the one-time fuse and the time limit circuit
breakers could be applied up to 400-percent of motor full-
load current per paragraph 430-52-(a).
The most common device used for motor running over-
current protection is the noncompensating thermal overload
relay. Overload relay heater elements are applied on the basis
of a code designation with a range from minimum to maxi-
mum motor full-load amperes for each code designation. The
44must trip" rating of the element is 125-percent of the mini-
mum application value of the range and 115-percent of the
maximum application value of the range. The operating
performance for thermal overload relays is outlined in para-
graph 109 of UL 508 which requires that an overload relay
when tested at an ambient temperature of 400C shall ulti-
279
mately trip on 100-percent of the current element rating, and
in not more than 8 min on 200-percent of the element rating,
and in not more than 30 s on 600-percent of the element
rating. Thermal elements were required to be used in only
two of the three-phase conductors on any three phase, three
or four wire, grounded or ungrounded system per Table 430-37.
With the release of the 1968 NEC, several changes were
introduced in the area of motor running overload and branch
circuit protection. The most significant change that was in-
cluded in the 1968 Code occurred in paragraph 430-52. This
change allowed for the first time the use of an instantaneous
trip circuit breaker (without time delay) provided the breaker
was adjustable and if part of a combination controller having
overcurrent protection in each conductor and the combination
was especially approved for the purpose. The setting of the
breaker should be adjustable over 700-percent to a maximum
of 1300 percent of the motor full-load current.
Prior to this change as stated previously, the only policy
which was universally accepted as a safety selling feature was
the inclusion of UJL listed components within the combination
controller. We have known for some time that this policy
alone has not provided the ultimate in motor circuit protection
especially in the area of motors having full-load current in
the range of 6 A and less. Data are available that indicate as
late as 1970 that approximately 16 percent of all electrical fires
recorded in the United States were caused as a result of motor
failures [3]. This figure was a 3-percent reduction over the
figures given for 1969.
In the 1968 NEC on three-phase systems, three heaters were
required to be used when part of a combination controller
employing an instantaneous trip circuit breaker. With the
introduction of the 1971 NEC, this requirement in Table
430-37 was extended to all three-phase systems unless pro-
tected by other approved means.
NORMAL OVERLOAD PROTECTION
In general, motor overload running protection is provided by
one of two major classes of protectors: 1) integral with the
motor or 2) remote from the motor. In the first class, motor
overheating is detected by temperature sensors imbedded
directly in the motor winding. When the winding reaches a
predetermined temperature level indicative of an unsafe condi-
tion which could lead to motor failures, the sensing device
operates to de-energize a remote controller which removes the
motor from service. This method is perhaps the most positive
since the actual temperature of the winding is measured
directly, and no compensation for ambient temperature or
other considerations need be made. While it is the best method
to use in theory, it is not in widespread general usage because
of the high cost and nonavailability of the special motors.
The second major class of overload protection and by far the
most common method in use, employs current sensing devices
located remotely from the motor. This type protection may
take the form of fuses, dashpot overload relays, or thermal
overload relays. Thermal relays depend on the heating ability
of the motor current to actuate their protective mechanisms.
Currents that exceed the motor full-load ampere rated values
cause insulation failures due to overheating. Current levels
280 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, MAY/JUNE 1973
tend to increase as the quality of the insulation deteriates.
Most motor failures or burnouts are caused by currents which
exceed the rated value for the motor.
Most control manufacturers have a type of thermal overload
relay that employs the use of either bimetals or solder pots.
Either of these two latter methods give more protection to
the motor per dollar of investment than any other method, and
hence are in widespread general usage. In applications where
automatic reset, ambient compensation, and adjustable current
ranges are required, the bimetallic type of overload relay is
the only type relay that can be used [5].
Bimetallic thermal overload relays are generally sized in
accordance with the size controller with which they are
applied. The individualized motor protection is accomplished
by the use of a large range of interchangeable heaters. Para-
graph 430-6(a) of the 1971 NEC indicates that separate
motor-running overcurrent protection shall be based on the
motor nameplate current rating. With this information avail-
able, the actual application is outlined further in paragraph
430-32 of the 1971 NEC which specifies the trip setting in
percent of motor full-load amperes. Additional information is
required in making this selection including a knowledge of the
service factor of the motor and the temperature rise of the
motor. A typical relay setting for a motor having a service
factor not less than 1.15 would be 125 percent of motor
full-load current.
Heaters are available in ranges with approximately 0-percent
steps, and a relatively large selection is necessary to satisfy all
ranges of motor loads. The heater trip rating is 125 percent
of the minimum value for each ampere range. A motor having
a service factor less than 1 .15 must be protected by an over-
current device rated to trip at not more than 1 5 percent of
the motor full-load rated current. To select a heater for this
application merely requires one to select the next lowest rated
heater from the selection tables.
Considerations must also be made for the ambient in which
the overload relay is applied. Relays are designed for 400C
continuous duty. Should the relay be used in an area where
the temperature is greater than the ambient temperature at the
motor, then the heater will need to be decreased 1 percent per
degree to compensate for the variation in temperature between
the location of the overload relay and the motor. If this
variation approaches 200 to 300C, then it is recommended
that ambient compensated relays be used. Per paragraph 1 13
of UL 508, an ambient compensated relay must perform
acceptably when subjected to performance tests from para-
graph 109 at ambient temperatures of 250C, 400C, and 500C.
All manufacturers provide a series of tables showing available
heater ratings usually listed by code numbers for a given
range of motor full-load currents. One such chart is illustrated
in Table I. Instructions are generally provided to determine
the proper heater selection for various ambient conditions
and service factors. The selections are not difficult.
Proper selection of the overload relay should also include a
prior knowledge of the locked rotor capability of the motor.
Most modern day motors have an average locked rotor
capability of 600 percent. Most thermal overload relays will
trip at this 600-percent level in 20 s, although paragraph 109
TABLE I
NONCOMPENSATED ENCLOSED CONTROLLERS (STARTERS.)
Block Type Overload Using Three
Heaters-Motor Full-Load Amperes Heater Selection
1.82-1.99 H 24
2.00-2.19 H 25
2.20-2.39 H 26
2.40-2.63 H 27
2.64-2.89 H 28
2.90-3.17 H 29
3.18-3.47 H 30
3.48-3.79 H 31
3.80-4.11 H 32
4.12-4.55 H 33
1) When motor and overload relay are in the same ambient and the
service factor of the motor is 1.15 to 1.25 select from above.
2) If the service factor is 1.0 or a maximum of 115-percent protec-
tion is desired, select one size heater smaller.
3) If the motor and overload are in different ambients, select heaters
from the table using adjusted motor currents as follows: decrease rated
motor current 1 percent for each °C motor ambient exceeds controller
ambient. Increase rated motor current 1 percent for each °C controller
ambient exceeds motor ambient.
For ambient compensated overloads, use the table as given.
of UL 508 requires that it trip in not more than 30 s. Fast
trip relays are available for special motor applications where
shorter lock rotor times are possible such as in hermetically
sealed motors.
MOTOR FAILURES: BEYOND OVERLOADS
Motor branch circuit short-circuit protective devices are
applied generally to protect the motor circuits for currents in
excess of locked rotor values over 600 percent of motor full-
load rated current. Any current in a motor branch circuit
above locked rotor values, at any time other than start-up
which generally subsides in a few seconds, can be described
as a fault current. The amount of fault current that can occur
is a direct factor of the system short-circuit capability and the
impedance of the system up to the point of fault. This value
can vary all over the board depending upon the type and
location of the point of fault.
Insulation breakdowns in motor windings caused by over-
heating are the prime causes of most motor failures. With the
competitive trend in industry, the usage of motors has been
increased in terms of heavier loading, increased cycle times,
and longer service periods. This fact has caused motors to be
run for longer periods of time at higher temperatures than in
the past, thus reducing the effective life of even the best insu-
lation materials.
Most faults that originate as a result of insulation break-
downs in motor windings are initiated at relatively low levels
of fault current on the order of 10 to 20 times motor full-load
current ratings. The reasons for this should be fairly obvious
when one considers the total impedance in the motor circuit.
A typical system illustrating this point is shown in Fig. 1. In
this example, a maximum short-circuit capability at the line
side terminals of the combination controller of 18 000 A rms
symmetrical has been assumed.
With the impedance values shown, it can easily be seen that
the amount of fault current available at the load side terminals
of the combination controller for a source capable of delivering
 WHITT: MOTOR CIRCUIT PROTECTION
480 VOLT
SOURCE
v AVAILABLE SHORT
CC IRCUIT CURRENT
18,000 AMPS
NSTANTANEOUS
TRIP CIRCUIT I 277V 0.0154
BREAKER (MCP) 1) 18,000
COI O IL RESISTANCE= 0.051
J
CONTACTOR IMPEDANCE= NIL
L_ J fashion until total failure occurred.
OVERLOAD
RELAY RESISTANCE= 0.160
H32 HEATER H32
0.2264
SHORT CIRCUIT CURRENT
MOTOR LEADS AT COMBINATION
CONTROLLER TERMINALS
MO TOR
277V 1220A.
0.2264
Fig. 1. Motor circuit fault currents.
18 000 A at the lineside terminals can be less than 2000 A.
When the resistance of the load side conductors and a portion
of the motor windings are also considered, then it can also be
seen that the total fault current will continue to drop to a value
that can certainly be within 10 to 20 times the motor full-load
ampere rating.
Historical data indicate that approximately 65 percent of all
combination starters sold are in the size 0 and size I range.
Data likewise indicate that the vast majority of heater sizes
utilized fall in the range between 2.64 and 7.9 A. On a 480-
V system, this clearly indicates that the vast majority of motors
used are less than 5 hp. For a 5-hp motor the most likely
fault could lie between 76 and 152 A.
The probability of high-level faults occurring after initial
motor start-ups is minimal. The most likely cause of a high-
level fault is accidental such as might occur when a wiring
error exists during initial hookup. Under such circumstance,
the impedance of the system components still react to limit
the amount of actual fault current. With the large blocks of
power available today in our industrial plants, these industrial
systems can theoretically deliver high short-circuit currents and
proper equipment applications must be made to insure that the
high faults can be cleared safely.
To determine the way a motor reacts enroute to failure,
several motors were tested to failure by deliberately locking
their rotors. Actual tests were conducted with a circuit
capable of delivering 10 000 A rms symmetrical.
Three-phase oscillograms of each motor failure test were
made. One phase of one oscillogram is illustrated in Fig. 2.
In the three-phase oscillogram the exact current rise varied in
each phase. In no case, did the fault current exceed 50 times
the normal full-load current rating of the motor. A number
of tests were conducted and the same general conclusions
applied in the majority of cases.
Concentrating on the oscillogram in Fig. 2, it can be seen
that the failure actually progressed in steps. The first step
above locked rotor current occurred at point "A" and was
approximately twice the locked rotor value. The current
continued along at this level for another 42 cycles to point
281
Fig. 2. Locked rotor test oscillogram.
"B" and then stepped again to a value three times locked rotor
value. This fault current continued in steps in more rapid
Again, the majority of motor failures are initiated as a result
of very low-level faults. If they are not cleared promptly they
can result in much higher level faults which tend to be more
destructive to the motor itself, the branch wiring and the
motor controller components associated with it.
MOTOR BRANCH: CIRCUIT SHORT-CIRCUIT PROTECTION
Ideal protection, as the name implies, is total and complete
protection in which the motor and motor control components
are protected by the minimum number of coordinated com-
ponents avoiding all circuit redundancy. Ideal protection
should also allow for the minimum amount of exposure to
plant maintenance personnel during times of equipment
servicing.
Total and complete protection of all control components is
impractical under all conditions. This fact is recognized in
UL 508 under paragraphs 140 and 141 as an example. In
paragraph 140, under certain conditions it is recognized that
heaters rated less than 3.75 A may burn out when protected
by a 15-A fuse rated at more than four times motor full-load
amperes. In paragraph 141, welding of contacts of the con-
troller is not considered a failure.
The performance criteria for combination controllers mounted
in motor control centers is outlined in the National Electric
Manufacturing Association (NEMA) Standard ICS 2-321H
paragraph 2-322.42.10 [4]. The basis for acceptance under
this criteria includes the following.
a) Fault current must have been interrupted by the branch
circuit protective device.
b) Immediately following the short-circuit test, the unit
shall withstand a dielectric test of twice rated voltage at
60 Hz for 1 min on the line side of the disconnecting means.
c) If fusible disconnect device, contact welding is acceptable
if normal operation of the operating mechanism will break
the weld.
d) A combination motor control unit or feeder tap unit may
require repair or replacement.
e) The operating mechanism for the disconnect device and
the door interlocks shall permit opening of the door.
f) Stab-in assemblies and vertical buses at the point of con-
tact shall be in essentially the same mechanical and electrical
condition as before the test.
g) The unit door must remain closed in its normal position
and shall operate normally.
Coordinated protection consists fundamentally of three
distinct segments: 1) overload or motor running protection,
2) low-level short-circuit protection, and 3) high-level short-
circuit protection.
282 8EEE TRANSACTIONS ON INDUSTRY APPLICATIONS, MAY/JtJNE 1973

'IABLE It
MCP CONTINUOUS AMPERE RATING AND PIN POSITIONS

MCP Trip Settings

Motor Full-Load MCP Continuous Use with Lock Positions
Current,Amperes Rating MCP Catalog Number Starter Size Minimum 1 2 3 4 5 6 Maximum

0.35- 0.87 1 MCP0312 0 4 4.5 5 6 7.5 9 10 12

0.62- 1.8 3 MCP0322 0 7 8 9 11 13 16 19 22
1.5 - 4.9 7 MCP0358 0 18 20 25 30 36 43 51 58
4.2 - 14.0 15 MCP03150 0 50 54 62 75 90 110 130 150
8.5 - 25.5 30 MCP13300 1 100 110 120 150 185 220 265 300
13.8 - 40.6 50 MCP23480 2 160 180 210 250 320 380 430 480
23.0 - 86.5 100 MCP331000 3 275 300 400 500 625 725 875 1000
38.5 -131.0 150 MCP431800 4 575 600 750 900 1100 1250 1500 1800

The function of any overload or motor running protection TABLE I[I

MCP APPLICATION: BASED ON RATED MOTOR FULL-LOAD AMPERES
device is to remove the motor from service thus protecting
both the motor and circuit components from excessive hieating NEMA MCP MCP Trip
during prolonged overload conditions and/or failure of the Motor Full-Load Controller Catalog Setting
Ampere Range Size Number Pin Setting
motor to start. This level of protection extends up to the
level of locked rotor current of the motor being protected. 1.5-1.8 0 MCP0358 20
As stated previously motor running protection can mIost 1.9-2.2 25
2.3-2.7 30
economically be accomplished by a thermal overload relay 2.8-3.2 36
mounted remotely from the motor and most likely in the 3.3-3.8 43
3.9-4.4 51
combination controller enclosure. The actual level of protec- 4.5-4.9 58
tion is determined by the selection of proper lheater elemnents
after taking into consideration the motor full-load current General 1) Selection of MCP size is based on controller size and motor
rating, the service factor built into the motor, and the ambient full-load amperes rating.
temperature in which both the motor and controller are "minimum." 2) MCP is shipped from factory with trip setting preset on
mounted. Various types and designs of overload relays and 3) Adjustment pin is contained in envelope with the MCP with
installation instructions printed thereon.
heaters are available to provide faster or slower tripping times Applicationi
depending on the maximum locked rotor time designed into 1) Determine motor full-load amperes and select pin setting from
the motor. All of these same considerations must be made ampere. above table or to a value not exceeding 13 times motor full-load
whether the disconnecting device in the combination con- 2) Insert pin in dotted circle opposite pin position shown.
troller is a breaker type or a switch and fuse combination. 3) For maximum protection, depress and turn pointer on MCP to
successively lower positions until the MCP trips on motor start-up.
Low-level faults begin at current levels above locked rotor After this position is determined, then adjust upward to the next
value. The fastest known method of cleanrng low-level faults higher setting. Intermediate steps between marked pin positions for
setting convenience.
is with the use of an instantaneous trip circuit breaker and
specifically the type MCP motor circuit protector. The MCP TABLE IV
is the first device of its type designed specifically for protec- COMBINATION CONTROLLER APPLICATION RATINGS
tion of motor branch circuits in accordance with Article RMS SYMMETRICAL AMPERES
430-52 as it appeared in the 1968 and currently in the NEMA Size 240 V 480 V 600 V
1971 NEC.
The MCP is an instartaneous trip circuit breaker containing Oa s50000 50 000 b50 000
no thermal element but, containing three specially designed 0,1,52,3,4 50 000 18 000 14 000
and calibrated solenoid coils to provide quick, sensitive pro- aRatings apply for circuits requiring the use of 3 and 7 A MCPs.
tection of motor circuits in the low-level fault area. Article bMCP,s when used with combination controllers in (W) motor con-
trol centers with drawout stabs have been tested and certified for
430-52(c) of the Code specifies that such a device shall be application to 22 000 A.
adjustable over 700 percent to a maximum of 1300 percent
of motor full-load amperes. This requirement is accomplished
by a uniquely designed magnetic trip adjusting cam having as applied to specific motor full-load ampere ratings is shown
eight positions and locking provisions to insure that the in Table III.
1300-percenit level is not exceeded. Type MCP motor circuit protectors are designed specifically
The type MCP motor circuit protector is available in one for use in a combination controller, and the combination of
physical size having eight separate continuous current ratings MCP and controller components determine the interruption
to cover all application requirements for combination con- rating. As stated earlier, the most common faults that occur
trollers through NEMA size 4. There are four ratings available do so at rather low levels of fault current. This is partially
for size 0 starters: 1, 3, 7 and 1 5 A. There is one size available due to the resistance and/or impedance of the circuit com-
for each starter size, 1, 2, 3, and 4: 30, 50, 100, and 150 A. ponents including the heater elements which tend to reduce the
Complete available ratings along with possible trip settings are actual level of fault current let-through although the system
shown in Table II. An example of typical pin position settings may theoretically be capable of much higher values. With this
WHITT: MOTOR CIRCUIT PROTECTION 283

TABLE V
PHASE
CURRENT LIMITER/MCP APPLICATION CROSS REFERENCE

Continuous Current Current Limiter MCP

Rating Catalog Number Catalog Numbera
3 EL 3003 MCP 0322
7 EL 3007 MCP 0358
15 EL 3015 MCP 03150
30 EL 3030 MCP 13300
50 EL 3050 MCP23480
100 EL 3100 MCP331000
_ __ _=_ ___ _--__. --- 110X' 150 EL 3150 MCP431800
aln the above MCP catalog identification system, the first number
Fig. 3. Clearing time for typical MCP. indicates starter size, second number indicates three-phase, and the
remaining digits indicate maximum trip setting.

PHASE
3) locking pin for limiting trip setting to a maximum of
1300 percent of motor full-load amperes;
4) available with internally mounted shunt trip and/or
auxiliary contacts for control and indicating circuitry.
In addition to the preceding, the MCP has several distinct
advantages when compared to other types of devices that could
be used for motor branch short-circuit protection including the
following:
Fig. 4. Clearing time for typical dual element fuse.
1) simultaneous opening of all three phases-single phase
protection;
thought in mind, combination controllers utilizing MCPs have 2) fast operation on low level faults;
been assigned application ratings in line with Table IV. 3) resettable;
The MCP is designed to open instantaneously in one cycle for 4) insensitive to ambient temperatures;
fault currents that exceed the trip setting. Because of this 5) can be field tested;
design, the MCP provides the fastest means known to clear 6)
safety;
low-level faults. Dual element fuses are perhaps the most 7)
uniform size for all ratings-allows for common operat-
common type of fuse used today to provide redundant motor ing mechanisms;
running protection as well as motor branch circuit short-circuit 8) compact size;
protection. Pei Table 430-152 of the NEC, dual element fuses 9) low-operating cost, minimum downtime, replacement
may be applied as high as 175 percent of motor full ampere not required;
load rating, but per exception 430-52.(b) this may be extended 10) can be opened with remote control devices.
to 225 percent.
Extensive comparison tests have been conducted on simnilarly For systems capable of delivering high levels of fault current
rated low-level test circuits to study the clearing times of both in excess of the rating of the combination controller utilizing
the MCP and dual element fuses. In the case of the dual ele- the MCP alone, a new three-pole current limiter has been
ment fuses, the application level has been at 125 percent-not
developed. The current limiter is a unique design of a three-
175 percent. The MCP has in all cases been set oni a pin phase silver, sand, current limiting fuse that is designed to be
used in conjunction with and connected to the load side of
position corresponding to 1300 percent of motor full-load a type MCP motor circuit protector. With the addition of the
rating. In every case, the MCP has cleared the circuit in one current limiter, the MCP/current
cycle as shown in Fig. 3. The dual element fuses have always be applied on all circuits with faultlimiter combination can safely
capabilities up to 100 000 A
taken longer varying anywhere from a low of 12 cycles-on
one phase-to a high of 80-90 cycles. One such oscillogram
rms symmetrical.
is illustrated in Fig. 4. In this case, phase two fuse cleared in The current limiter is a compact three-phase assembly avail-
12 cycles while phases one and three cleared after 22 cycles. able in seven continuous current ratings including: 3, 7, 15, 30,
The level of fault current available was approximately 35 50, 100, and 150 A. Complete catalog references of the
times rated motor full load. Test results depicted in the current limiters along with associated MCPs to be used there-
with
preceding figures illustrate the distinct advantage of the MCP limiter is shown
are in Table V. Each of the three poles of the
equipped with a spring loaded indicator that wfll
in clearing low-level faults.
The motor circuit protector has several features that must extend beyond the limiter housing when a fault is interrupted
be mentioned, including the following: by the limiter identifying the faulted phases. A blown current
limiter is an indication of a serious circuit problem that must
1) compact, single frame size for all starters through size 4; be corrected before restoring service.
2) single adjusting cam for adjusting trip setting of all three The design of the individual MCP and current limiter is
poles simultaneously; coordinated so that normal fault currents up to 50 or more
284 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, MAY/JUNE 1973

times the continuous rating of the MCP will be interrupted

automatically by the MCP below the operating level of the 10%° TOLERANCE
H32 HEATER -\ RANGE
current limiter. Only the very high faults that occur rarely
outside test laboratories will cause the current limiter to
interrupt and clear the fault. Any fault of sufficient magnitude
to cause the current limiter to interrupt will also cause the MCP
ADJUSTMENT rI" 51 AMP MCP
MCP to unlatch. Since the interrupting speed of the current RANGE PIN SETTING
limiter is much faster than the MCP for high-level faults, it will .L
18 - 58 AMPS
clear the fault and the MCP will follow through opening all Lfi
three phases. Thus, the MCP/current limiter conmbination con- \_ 'I CURRENT LIMI TER
EL 3007
troller will provide a maximum degree of protection while
eliminating needless fuse melting and utilizing the MCP to
safely clear all low-level faults which represeint the majority of OVERLOAD MC P CURREN T
fault interruptions. RELAY LIIMITER
To illustrate the three controller components of a coordi- CROSSOVE:
900 AMPS-
nated system, a typical coordinated tripping curve is shown
in Fig. 5. The overload relay curve shows relay response up to
t A ~~/i
approximately six to seven times motor full-load current. The CURRENT
type MCP motor circuit protector then reacts to clear low-level
Fig. 5. Typical coordinated tripping curve.
faults above those values to approximately 150 to 200 times
motor ftull load. Finally, if required, the current limiter opens
development of the type MCP motor circuit protector, better
and clears the circuit for all high-level faults above this value to
systems capable of delivering 100 000 amperes rins symmetrical. protection than ever before is now possible for motor circuits
in the area of low-level faults where most faults occur.
POSITION OF UNDERWRITERS' LABORATORIES By using the type MCP motor circuit protector in conjunc-
The use of instantaneous trip circuit breakers was first intro- tion with the current limiter, completely coordinated short-
duced in the 1968 NEC under paragraph 430-52. In the 1971 circuit protection can be achieved on motor branch circuits
Edition, the use of motor short-circuit protectors that could capable of delivering up to 100 000 A rms symmetrical fault
be used in lieu of either conventional fuses, instantaneous currents. The coordination thus established provides for maxi-
trip, or time limit circuit breakers was included for the mum circuit continuity and minimizes exposure of electrical
first time. components to maintenance personnel maximizing their safety.
UL, Inc. has been working since the introduction of the Complete coordinated motor circuit protection can thus be
1968 Code to provide a set of standards under which instan- achieved with each component in the combination controller
taneous trip circuit breakers could be listed. Only recently performing its designed function, namely.
have the first standards proposals covering these new types of 1) Thermal overload relays providing motor running and
devices been released under UL subjects 489 and 508. The overload protection up through locked rotor current values.
first was released 724-24 and covered: "Proposed requirements 2) Motor circuit protector providing branch circuit short-
for combination magnetic motor controllers intended for use circuit protection in the area of low-level faults.
on circuits having available fault currents in excess of 10 000 A 3) Current limiter providing branch circuit short-circuit
rms symmetrical." protection for those rare high-level faults that can occur on
The second proposal was released on 72-4-25 and covered: systems capable of delivering up to 100 000 A rms symmetrical
"Proposed requirements for combination motor controllers fault current.
employing instantaneous trip circuit breakers." With the new Standards proposals just released by UL, Inc.,
Combination controllers using type MCP motor circuit pro- standards are now available for examining combination con-
tectors have now been submitted to UL for listing in line with trollers using motor circuit protectors, and UL listing should
the requirements outlined in the preceding proposals. UL follow shortly.
listing is expected in the near future. REFERENCES
CONCLUSION [1l1 ational Electric Code 1971, NF PA no. 70-1971; also ANSI
CI-197 1.
Prior to the 1968 Edition of the NEC, the use of instanta- [2] Itndustrial Conitrol Equipment, Underwriters' Laboratories, Inc.
Standard For Safety No. UL 508; also ANSI C33.76-1971.
neous trip circuit breakers was not recognized as a method of [31 IAEI News, Sept./Oct. 1971.
providing motor branch circuit short-circuit protection. With [41 NEMA ICS-1970 Industrial Controls and Systems.
[51 P. T. Anderson, "Applying thermal overload relays," Plant Eng.,
the recognition of instantaneous trip circuit breakers and the July 9, 1971.

Raymond 0. D. Whitt (SM'62), for a photograph and biography-please see page 155 of the
March/April 1973 issue of this TRANSACTIONS.