A.C. Motor Protection and Faults Aim

Module : Electrical Engineering MT 3011
Topic : A.C. Motor Protection

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A.C. Motor Protection and Faults
Aim
Understand the safe operation of a.c. induction motor
LEARNING OUTCOMES
• Explain the principle of operation of thermal and magnetic types of motor

overload protection.
• Explain the advantage of using thermistor for motor protection.
• Describe how overload setting for a motor is determined.
• Describe the usual cause of single phasing.
• Explain the difficulties of protection against single phasing and how these might
be overcome.
• Explain the effect of low voltage on a.c. induction motor.
• Explain the effect on an a.c. motor which is supplied with a current of 50Hz when
its designed frequency is 60Hz and vice versa.
• Explain the steps to be taken to counteract the effects of operating an a.c. motor
at a frequency other than its designed frequency.
• Explain the causes of overheating in induction motors.
• State the preventive measures to counteract overheating.
Overview
This lesson provides student with an understanding of the need for protection
against over-current fault during the operation of an induction motor. The operation
of protection devices found in motor circuits is explained.
Motor Protection and Faults
Necessity for Over-current Protection
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Protection of motors is required mainly to prevent overheating which can cause

deterioration of winding insulation and burn-out, which is a severe case of
overheating. Overheating as a result of overload, stalling, single-phasing or
prolonged starting period can be detected by a rise in line current and temperature
increase in the windings.
A device which monitors only the line current cannot detect overheating due to high
ambient temperature or poor cooling due to block air passages, star-delta starter
remaining in the star connections, and starting and stopping too often. Overheating
in this case can only be detected by temperature rise within the windings.
a) Magnetic Circuit Breaker
The circuit breaker is used to protect circuits against short circuit faults in the same
manner like a fuse. A fuse burn out but a circuit breaker trip. It can be reset and
use again.
In normal operation, current flow through contacts that are held closed by an
armature. Normal circuit current which flows through the coil is insufficient to
produce a significant magnetic flux to attract the armature. When too much current
flow through the coil, the armature is attracted, initiating an unlatching action,
causing the circuit to open. After the fault that causes the excessive current flow is
rectified, the circuit breaker can be reset and used again.
Magnetic Element
Contact
Current Flow
Figure 1
b) Thermal Overload Relay
Motors need to be protected against light overload. The overload protection will
operate at 10% to 20% above the rated full load current.
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The thermal overload relay has three bi-metallic elements, one for each phase of the
three phase lines. The bi-metallic strip consists of two metals sandwiched together.
One end of the bi-metal is fixed while the other end which is free, bends when
heated. The motor line current passes through the heater. When the motor load
current is normal, the bi-metal elements bends slightly. Excess current passing
through the bi-metals causes them to bend much more. The three bi-metal
elements are linked together through a plastic slide which moves to the right. A
series of lever movement causes a normally close trip contact to open. In the motor
control circuit, this n.c. trip contact is in series with the main contactor coil of the
motor starter. With the opening of the trip contact, the coil gets de-energised, the
main contactors on the supply lines open, and the motor stops.
In this way, the motor is prevented from being overheated. If there is not overload
protection, the excess heat would have over a period of time, damage the insulation
so much that the motor would have burnt out.
Auxiliary Circuit Current
Normally closed
contact
Bi-metallic strip
Motor Line Current
Heater
Off Load Position Tripped Position
Figure 2
c) Fuses
Short circuit protection is also a requirement for motors of over 0.5 kW. Fuses of the
cartridge/HRC design may be employed to provide the necessary rapid interruption
of high fault current. Since short circuit current may be high enough to damage
normal motor contacts, the fuses may be arranged to break fast first in the event of
short circuit. The secondary function of fuses is to provide back-up for the other
protective devices.
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d) Thermistor Protection of Motor Winding
The thermistor is thermal device which can be used in conjunction with an electro-
magnetic overload trip. One of these inserted in each of the three windings would
detect overheating from any cause. Thermistor are available with either a positive
or negative characteristic. The former type are more definitive in operation because
there is very sharp rise in resistance at a particular temperature (as opposed to
gradual drop in resistance of the other sort). Positive thermistor can be connected
simply in series and the very small current which passes through them normally is
cut off by the effect of overheating in any one of them. Cessation of the minute
checking current is used as the signal to operate the motor trip.
Trip
(51b)
Amplifier
Thermistor
Figure 3
e) Electronic Overload Relays
Electronic overload relays are another option for motor protection. The
features and benefits of electronic overload relays vary but there are a
few common traits. One advantage offered by electronic overload relays
is a heaterless design. Electronic overload relays can detect a phase loss
and disconnect the motor from the power source. This feature is not
available on mechanical types of overload relays.
For more info, please browse:
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http://www.icc-gb.com/index.html
Solid State
Overload Relay
+44 (0) 118 9700010
sales@icc-gb.com
EOCR-AR
ELECTRONIC OVERLOAD RELAY WITH AUTO RESET
Introduction
1) Adjustable Auto reset Time(0 - 120 seconds)
2) Single Timer for starting and trip Delay
3) Overload and Phase Loss Protection
4) Visual Current Setting Aid and Trip Indication(LED)
5) Flexible Power Supply
(90 to 260VAC, 180 to 480VAC)
6) Fail-safe Protection
Description
Two of the three phase motor currents are monitored by current
transformers.
The CTs form integral part of the relay, and external CTs are required for
currents
above 60Amps. internal solid state circuitry compares the actual motor
current
with the preset load current, set by the Load Knob(Load). When current
level is
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greater than the preset point. due to overload or single phasing,
red LED illuminated and after the elapse of the preset delay time,
SPDT relay switches contact. The red LED remains illuminated, indicating
an overload trip has occurred. After the elapse of preset Reset Delay
Time(maximum 120sec), it resets automatically. immediate reset with of
Reset button or remote electrical reset by interrupting control power, is
possible. the starting delay and trip delay times are simultaneously set
with single O-Time Knob and these timing functions are not independent.
Test button provides means of testing the operation and integrity of the
device with or without motor running. The actual load current can be
determined with visual aid of LED(no Ammeter required).
Simply adjust the the Load Knob slowly anti-clockwise until red LED
flickers.
The flickering red LED indicates 100% of actual motor current.
How to set up
1) Set the trip delay time at the O-Time Knob,
not less than normal run-up time of the motor.
2) Set the desired reset time on the Reset time Knob(R-time)
3) With the control power on, depress Test button,
and hold. Verify the red LED illuminates and tripping of the
relay after the preset time. Red LED remains on until relay resets
automatically after the preset delay.
4) When commissoning relay or motor, set the load knob current to
the full load amperes, and engage the load.
Then turn the load knob slowly CCW, until the LED flashes,
where the 100% of actual load current is indicated.
Set the Load Knob to the desired trip current.
5) Periodic testing of the Test facilty is required to ensure full protection
and regularly as Preventive Maintenance.
ORDERING INFORMATION
Dimension
Typical application
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Specification
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Single Phasing
Causes and Effects of Single-Phasing
The loss of current through one phase in a 3-phase supply is described as single
phasing. This open circuit in a phase is often caused by:
a) blown fuse
b) faulty contact
c) broken wire or loose connection
With single phasing fault a motor will stall during starting. A running motor continues
to run with the fault.
A motor running with a single phase fault will carry excess current in the remaining
supply cables. There will be an unbalanced distribution of current in the windings.
It will be seen that at full load, the current in winding A is nearly 3 times its full load
current and in windings B and C it is about 1.3 times above full load current. The
line current is about 2.5 times the rated full load current.
Single phasing in a running motor can be detected by overload devices in the supply
lines.
A single phased motor arranged for automatic starting will not self-start and if
overload protection fails to operate, will result in overheating. Overheating in a
stalled or running motor will cause burn-out of the overload windings.
It is possible for single phasing in a lightly loaded motor to remain undetected by

electro-magnetic trip (or thermal overload trip) on the supply lines which monitors
the line current. Improved protection is given by thermistors placed in the windings
to measure thermal effects. Alternatively, the differential type of overload relay may
be used.
The table below shows typical values of the line and phase currents under various
loading during a single phasing fault.
Single phase Condition

% of full load rating % of rated full load current
IL1 and IL3 IB and IC IA
60 102 62 131
70 130 79 131
100 243 129 285
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Examine the condition when the motor is running at 60% of full load rating when
single phasing occurs. The line currents are 102% of the full load value whereas the
current in winding A is 31% above its full load value. The line current will probably
not activate a line-connected overload relay. The motor continues to run. However,
local overheating in winding A of the motor will quickly result in damage.
Single Phasing - Full Load Condition
L1 L2 L3
Open-circuit in
L2
C B
Figure 4
General Effect of Voltage and Frequency Variation of Induction Motor
Induction motors are at times operated on circuits of voltage or frequency other than
those for which the motors are rated. Under such conditions, the performance of
the motor will vary from the standard rating.
Voltage variations of 10% on power circuits are allowed in most commission rules.
However, changing the voltage applies to an induction motor has the effect of
changing its proper rating in proportion to the square of the applied voltage. This a
5-hp motor operated at 10% above the rated voltage would have characteristics
proper for a 6-hp motor (6.05 to be exact), and operated at 10% below the rated
voltage those of a 4-hp motor (4.05-hp). It is obvious that if the rating of a motor
were greatly increased in this way, safe heating would frequently be exceeded.
Relation of Torque to Supply Voltage
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At constant frequency, the flux in the stator of the motor is directly proportional to the
supply voltage, just as in a transformer. If the voltage is halved, the flux of the
rotating field is also halved. At normal voltage, the motor develops a definite torque
at a curtain slip. At half voltage, the halved stator flux sets up a halved emf and
current in the rotor at the same slip.
The rotor poles of half strength now react against the halved stator poles to produce
approximately one quarter the former torque. It can be said that for a given slip the
torque is proportional to the square of the supply voltage.
The curves are shown for a motor having 300% breakdown torque at 20% slip and a
starting torque of 150% at normal supply voltage. Accordingly, at half voltage, the
breakdown torque is (½)2 or ¼ that at normal voltage and equal to ¼ of 300 or 75%.
The starting
0
torque is also
¼ of 150% or 10
37.5%. At
70% of 20
normal supply
30
voltage, both
breakdown 40
and starting
torque are 50 2 1
therefore 3
60
0.702 or
practically 0.5 70
of normal
supply 80
voltage, both
breakdown 90
and starting
100
torque are 50 100 150 200 250 300
therefore
0.702 or practically 0.5 of normal, giving a breakdown torque or 0.5 x 300 or 150%,
and a starting torque of 0.5 x 150 or 75% of that at normal voltage, as shown in
Figure 5.
Per Cent Slip
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Per Cent Full Load Torque
1. Slip-Torque at Rated Voltage

2. Slip-Torque at 70% Rated Voltage
3. Slip-Torque at 50% Rated Voltage
Figure 5
Now, consider a 3-phase squirrel cage induction motor driving a blower or

centrifugal pump. At rated voltage, the speed-torque characteristic of the motor is
given by curve 1 of Figure 6. To simplify the drawing the curve is given as two
straight lines. If we apply half the voltage the curve is given by curve 2. Because
the torque is proportional to the square of the applied voltage, the torques in curve 2
are only ¼ of the corresponding torque in curve 1.
The load torque of the blower varies nearly as the square of the speed. This typical
characteristic, shown by curve 3, is superimposed on the motor torque-speed
curves. Thus at rated voltage, the intersection of curve 1 and 3, is superimposed on
the motor torque-speed curves. Thus at rated voltage, the intersection of curve 1
and 3 shows the blower runs at 90% of the synchronous speed. On the other hand,
at half rated voltage, the blower rotates at only 60% of synchronous speed.
In general, a higher voltage will generally cause equipment to take excess current
and overheat. It will also cause motors to accelerate more rapidly and this may
overstress driven loads. A lower voltage is generally not so serious but may cause
motor to run slower and may cause motor to stall. Windage is poor and motor may
overheat.
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Torque %
200
(1)
100
(3)
(2)
0
20 40 60 80 100
Speed Synchronous Speed
Figure 6
When the frequency of the supply system is reduced
In a 60-Hz motor running on 50-Hz supply, the stator flux increases and the motor
magnetising current increases so that heating of the windings and of the iron also
increases. Thus a motor on reduced frequency will tend to run hotter.
However, a motor driving a fan also experience a reduction speed and torque which
bring about a reduction in load.
Any temperature rise may be compensated by a reduction in supply voltage.
A reduction in frequency brings about an increase in torque. The breakdown torque

and starting torque of a 60-Hz motor operating on a 50-Hz supply are about the
same if the voltage is reduced to 5/6 of its name-plate value.
In general, the full load torque of a 60-Hz motor operated at 50-Hz will be
approximately 6/5 of the 60-Hz full load torque.
When the frequency of the supply system is increased
In a 50-Hz motor running on a 60-Hz supply, the stator flux reduces and the motor
magnetising current reduces.
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However, a motor drivings a fan also experience an increase in speed and torque
which bring about an increase in load. The load current increases on account of the
higher load. Thus a motor on increased frequency will run hotter.
Any temperature rise may be compensated by a reduction in supply voltage.
An increase in frequency brings about a reduction in torque. The breakdown torque

and starting torque of a 50-Hz motor operating on a 60-Hz supply are about the
same if the voltage is increased to 6/5 of its name-plate value. This will ensure that
the load torque does not exceed the driving torque.
In general, the full load torque of a 50-Hz motor operated at 60-Hz will be
approximately 5/6 of the 50-Hz full load torque.
160
120
Torque, Nm 460 V, 60Hz

80 230 V, 30 Hz
40
0 300 600 900 1200 1500 1800

RPM
Figure 7 Effect of Changing stator frequency
Short Summary of Effect of Voltage and Frequency Variation
1. A motor will operate successfully on any voltage within ±10% of normal voltage
and for any frequency within ±5% of norminal frequency. If the voltage and
frequency both vary, the sum of the two percentages must not exceed 10%.
2. Changing the voltage applied to an induction motor has the effect of changing its
proper rating as to power factor and efficiency in proportion to the square of
the applied voltage.
3. Thus a 5 kW motor operated at 10% above the rated voltage would have
characteristics proper for a 6 kW motor (i.e. 1.12 x 5 = 6.05). Operated at
10% below the rated voltage it would have those of a 4 kW motor (i.e. 0.92 x 5
= 4.05).
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4. It is of course obvious that if the rating of a motor were greatly increase in this
way, safe beating would frequently be exceeded.
5. If the line voltage is too high, the flux per pole will be high. This increases both
the iron losses and the magnetising current with the result that the
temperature increases slightly and the power factor getting worse.
6. Starting current will be higher with excessive voltage and causes overheat.
7. If the voltage is less than 10% of the rated voltage, overheating, stalling and burn-
out can result. The torque generated is reduced and for a fixed load
(centrifugal pump or fan), the current will increase to maintain the required
output. Such operation will generally cause overheating.
8. If the line voltage is considerably below the rated voltage of the motor, the
maximum torque that the motor can develop may be so reduced that the
motor will stall on small overload.
9. When the frequency is reduced, it causes a reduction in speed. The starting and
running torque which is inversely proportional to the synchronous speed
increases. With a reduction in frequency, the full load current also increases
because stator flux increases and magnetising current increases. Hence, this
iron loss increase results in overall increase in temperature.
10. When the frequency is increased, it caused, it causes an increase in speed.

Stator flux reduces resulting in the lowering of magnitising current. However,
the higher speed will results in a higher load being driven. Hence the load
current will increase to cause overheat.
11. A 60 Hz motor can also operate on a 50Hz line but its terminal voltage should
be reduced to 5/6 of its rated value. The breakdown torque and starting
torque are then about the same as before and power factor, efficiency and
temperature rise remain the same.
12. A 50Hz motor operates well on a 60Hz line but its terminal voltage should be
raised to 6/5 of its rated value. The new breakdown torque is then equal to
the original breakdown torque and starting torque slightly reduced. Power
factor, efficiency and temperature rise remains satisfactory.
Motor Overload Protection
DOL starting introduce problems for overload and short circuit protection because of
the initial inrush of starting current (5 - 8 times f.L. current). The protective device
must be inoperative during the starting period but operative on normal moderate
overloads and on short-circuit and under stalled conditions.
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Motors are now rated on CMR basis i.e. they are not required to have any margin or
capacity for prolonged overload operation. This entails overload protection at a low
level say 15% to 25% overloads for short periods.
Overload protection should be set preferably at the working load current and not
according to the motor current shown on motor rating plate.
Under-voltage Protection for Motors.
AC motor which is stopped due to interruption of supply should be disconnected

from supply because on restoration it should not immediately switched on for the
following reasons.
(a) Operating personnel may be injured due to motor starting unexpectedly.
(b) With certain ac motors a definite sequence of starting operations must be

gone through.
(c)If all motors were to restart simultaneously the generators might be seriously
overloaded.
(d) Certain adjustments to the driven machinery may be necessary before re-
starting.
U/V (or no-volt) protection is provided by spring loaded motor contactor because it
will drop out when the supply volt is lost. When the supply returns the motor will not
restart until its contact coil is re-energised.
(a) Automatic starters under the control of float switches, pressure switches,
thermostat will restart immediately. If necessary these can be locked after a
supply failure.
(b) Contactors will function to close a circuit with the supply voltage reduced to
80% of normal for DC and 85% for ac as required by BS. However once they
are closed, they will hold on with very much lower voltages down to two-thirds
of normal and in some cases much lower. With an induction motor, the
available torque is proportional to the square of the voltage so that at 2/3
voltage the torque available will have fallen to 40%. It will therefore most
probably stall, causing considerable increase in stator current.
Cartridge Fuses
HRC fuses have silver wire enclosed in a quartz powder filled ceramic tube with
metal end caps. Arcing when this type of fuse blow is buried in the powder, fusion of
which in the arc path helps to extinguish it.
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HRC fuses can be used for very high fault levels, determination is negligible, they
have accurate time/current characteristics and reliability for discrimination; they are
safer. If accidentally inserted on a fault; there is not issue of smoke or flame;
cartridges are sized to ensure that the correct value fuse is inserted.
Replacing Fuses
It is prudent and sound practice when replacing fuses to replace all three. If any of
the replaced fuses are still intact they can be transferred to another use such as
lighting circuit where matching is not vital. Fuse clips and connections should be
examined when renewing fuses as an overload contact may cause operation below
the correct value.
Sample Solution
Explain the necessity of keeping electrical contactors clean and closed with a firm
contact pressure.
Describe briefly the functions of auxiliary contacts.
State how copper contactors are kept free of oxide formations.
The basic requirements of any pair of contacts are:
a) Low resistance of the contact material.

b) Low resistance between the two contact surfaces when they meet to make the
circuit.
Contacts in use are usually of copper for the sake of economy as well as its low
resistance. Copper oxide film readily forms on the copper tips. Since copper oxide
is not a good conductor, it must be eliminated by keeping contactors clean.
Also, a certain amount of pressure is required to keep two contact surfaces closed
sufficiently, to reduced what is called contact resistance.
A switch for example, which is operated many times will eventually reach a stage
when its spring weakened, with the result that pressure of the contacts is lost to
such an extent that heat is generated and a breakdown of the switch follows:
Within limits, the contact resistance varies inversely with spring pressure. The
higher the resistance of contact material the more the heat there will be when a
current pass along it. There is danger of contact welding occurring.
An example of auxiliary contacts are found in the contactors of a main switchboard.

Auxiliary contacts are operated by link mechanism and are of low power rating.
Auxiliary contacts are used for switching, interlocking e.g. operating relays,
indication lamps, etc in the control circuit.
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Copper contactors are kept free of oxide formation by regular cleaning with cleaning
fluids which are available for this purpose. Very fine emery cloth can be used.
Some Contactors are designed with a wiping action to remove copper oxide film.
Sample Solution
Give 3 applications of wound rotor type of induction motor on board ship and justify
reasons for its use.
1) electric winch
2) electric crane
3) electric windlasses
In order to minimise the surge of starting current to the wound rotor motor due to
high starting load, full resistance is inserted in the star-connected speed controller of
the rotor circuit. As the motor controller can be cut out of the rotor circuit until the
motor accelerates to its rated speed.
The insertion of resistance in the motor circuit also produce high starting torque and
also provides a means of adjusting the speed.
Figure below illustrates that the torque performance of a wound-rotor induction

motor is good whenever the full resistance of the speed controller is inserted in the
rotor circuit. The large amount of resistance in the rotor circuit causes the rotor
current to be almost in phase with the induced voltage of the rotor. As a result, the
field set up by the rotor is almost in phase with the stator field. If the two fields reach
a maximum value at the same instant there will be a strong magnetic reaction
resulting in a high torque output.
In all three cases given, a high starting and running torque is required. Hence for
this reason and a reduction in starting current, justify the use of a wound rotor
induction motor.
Sample Solution
Give 4 application of squirrel cage type of induction motor on board ship justifying
the reason for its use.
1) feed water pump

2) fresh water pump
3) bilge pump
4) auxiliary pumps
The 3-phase, squirrel-cage induction motor is relatively small in physical size for a
given horsepower rating when compared with other types of motors. It has good
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speed regulation under varying load conditions. A minimum of maintenance is
required with is type of motor because:
a) the rotor has no windings to become shorted.
b) there are no commutators or slip-rings to service.
c) there are not brushes to replace.
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Module : Electrical Engineering MT 3011

Topic : A.C. Motor Protection