Eric Assignm

I. INTRODUCTION TO ELECTRIC MOTORS...............................................................................................
3
I.1. Single phase induction Motor........................................................................................................................3
I.2. Wound rotor induction Motor.......................................................................................................................3
I.3. Capacitor-start induction motor.....................................................................................................................3
I.4. Synchronous motor....................................................................................................................................3
I.4.1. Single phase Synchronous motor...........................................................................................................3
I.4.2. Three-phases phase Synchronous motor................................................................................................4
I.5. Special Motors...............................................................................................................................................5
I.5.1. Stepper Motor.........................................................................................................................................5
I.5.2. Single phase series motor.......................................................................................................................6
I.5.3. Compensated series motor......................................................................................................................6
I.5.4.Universal motor.......................................................................................................................................6
I.5.5. Repulsion motor.....................................................................................................................................6
I.5.6. Repulsion start induction motor.............................................................................................................6
I.5.7. Hysteresis motor.....................................................................................................................................7
I.5.8.Eddy current clutch.................................................................................................................................7
II. ELECTRIC MOTORS PROTECTION..............................................................................................................7
II.1. Overcurrent Protection.................................................................................................................................7
II.2. Overload Protection.....................................................................................................................................7
II.3. Differential Protection..................................................................................................................................8
II.4. Other Motor Protection Devices..................................................................................................................9
II.4.1. Low Voltage Protection........................................................................................................................9
II.4.2. Medium Voltage Motor Surge Protection.............................................................................................9
II.4.3. Overvoltage.........................................................................................................................................10
II.4.4. Phase Failure Protection......................................................................................................................10
II.4.5. Phase Reversal Protection...................................................................................................................11
II.4.6. Ground Fault Protection......................................................................................................................11
II.4.7. Unbalance Protection..........................................................................................................................11
II.4.8. Short Circuit Protection......................................................................................................................11
II.4.9. Mechanical Jam...................................................................................................................................11
II.4.10. Load Loss Detection.........................................................................................................................11
II.4.11.Other Motor Protection Devices........................................................................................................12
II.4.12.Sizing Motor Overcurrent Protection.................................................................................................12
II.4.13.Types of Overcurrent Devices...........................................................................................................12
II.4.14.Standard Fuse Response.....................................................................................................................12
II.4.11.1. Standard (Non-Time Delay, Single Element) Fuses..................................................................12
Page 1 of 27 Industrial Safety and Maintenance

By Eric MWIZERWA (Kigali Institute of Science and Technology(0250 788 55 3598)
II.4.11.2. Time-Delay (Dual Element) Fuses............................................................................................13
II.5. Circuit Breakers.........................................................................................................................................13
II.5.1. Inverse CB Trip Curve........................................................................................................................13
II.5.2. Instantaneous Trip Circuit Breakers...................................................................................................14
II.6. Motor Overload Protection........................................................................................................................14
II.6.1. Magnetic & Thermal Overloads.........................................................................................................15
II.6.2. Magnetic Overload Relays..................................................................................................................15
II.6.3. Thermal Overload Relays...................................................................................................................15
II.6.3.1. Melting-Alloy Thermal Overload Relays....................................................................................15
II.6.3.2. Bimetallic Thermal Overload Relays...........................................................................................16
II.6.3.3. Automatic Reset Devices.............................................................................................................16
II.6.4.Electronic Overloads............................................................................................................................17
II.6.5. Fuses....................................................................................................................................................17
II.6.6.Overload Trip Time.............................................................................................................................17
II.6.7. Sizing Motor Overload Protection......................................................................................................18
II.6.8. Ambient Temperature Compensation.................................................................................................18
II.6.8.1. Ambient Compensated Heaters....................................................................................................19
II.7. Sizing Motor Protection Systems...............................................................................................................19
III.ELECTRIC MOTORS INSTALLATION.......................................................................................................20
III.1. General Guidelines to electrical Motors Installations..............................................................................20
III.2. Motor Start and Speed control..................................................................................................................21
III.3. Running 3-phase motors on 1-phase.........................................................................................................21
III.4. Self-starting static phase converter Run capacitor....................................................................................22
III.5. More efficient static phase converter Start capacitor...............................................................................22
III.6. Electronic variable speed drive.................................................................................................................22
III.7. Stepping a Permanent magnet stepper Motor...........................................................................................23
III.8. Samples on Installation of DC Motors.....................................................................................................23
III.8.1. Shunt wound Motors..........................................................................................................................23
III.8.2. Series Wound Motors........................................................................................................................24
III.8.3. Compound Wound Motors................................................................................................................24
III.9. Sample on installation of Induction Motors.............................................................................................25
III.9.1. Installation of Single phase Capacitor run-Capacitor start Motor.....................................................25
III.9.2. Star-delta starters with overload relay...............................................................................................25
III.10. Visual and Mechanical inspections........................................................................................................26
III.11. Possible relevant standards.....................................................................................................................27
IV. REFERENCES................................................................................................................................................27

I. INTRODUCTION TO ELECTRIC MOTORS
Many different energy efficiency standards for IMs are currently in use (e.g. NEMA and EPAct in USA, CSA
in Canada, CEMEP/EU in Europe, AS/NZ in Australia and New Zealand, JIS in Japan, and GB in China) with
new classes currently being developed in several countries around the world.
I.1. Single phase induction Motor
The single coil of a single phase induction motor does not produce a rotating magnetic field, but a pulsating
field reaching maximum intensity at 0o and 180o electrical.
A three phase motor may be run from a single phase power source. However, it will not self-start. It may be
hand started in either direction, coming up to speed in a few seconds. It will only develop 2/3 of the 3-φ power
rating because one winding is not used
I.2. Wound rotor induction Motor
A wound rotor induction motor has a stator like the squirrel cage induction motor, but a rotor with insulated
windings brought out via slip rings and brushes. However, no power is applied to the slip rings. Their sole
purpose is to allow resistance to be placed in series with the rotor windings while starting
I.3. Capacitor-start induction motor
A larger capacitor may be used to start a single phase induction motor via the auxiliary winding if it is switched
out by a centrifugal switch once the motor is up to speed. Moreover, the auxiliary winding may be many more
turns of heavier wire than used in a resistance split-phase motor to mitigate excessive temperature rise. The
result is that more starting torque is available for heavy loads like air conditioning compressors. This motor
configuration works so well that it is available in multi-horsepower (multi-kilowatt) sizes. It exists other
methods of placing the capacitor for different purposes like Cap. Run; Cap. Start-Cap. Run and Auxiliary
winding.
I.4. Synchronous motor

I.4.1. Single phase Synchronous motor
Single phase synchronous motors are available in small sizes for applications requiring precise timing such as
time keeping, (clocks) and tape players. Though battery powered quartz regulated clocks are widely available,
the AC line operated variety has better long term accuracy-- over a period of months. This is due to power plant
operators purposely maintaining the long term accuracy of the frequency of the AC distribution system. If it
falls behind by a few cycles, they will make up the lost cycles of AC so that clocks lose no time.
Above 10 Horsepower (10 kW) the higher efficiency and leading power factor make large synchronous motors
useful in industry. Large synchronous motors are a few percent more efficient than the more common induction
motors. Though, the synchronous motor is more complex.

Synchronous motor running in step with alternator
I.4.2. Three-phases phase Synchronous motor
A 3-phase synchronous motor generates an electrically rotating field in the stator. Such motors are not self
starting if started from a fixed frequency power source such as 50 or 60 Hz as found in an industrial setting.
Furthermore, the rotor is not a permanent magnet as shown below for the multi-horsepower (multi-kilowatt)
motors used in industry, but an electromagnet.
Large industrial synchronous motors are more efficient than induction motors. They are used when constant
speed is required. Having a leading power factor, they can correct the AC line for a lagging power factor.
The number of poles is n. For rotor speed in rpm, multiply by 60.
S = f120/n

Where: S = rotor speed in rpm; f = AC line frequency and n = number of poles per phase
Large industrial synchronous motors are self started by embedded squirrel cage conductors in the armature,
acting like an induction motor. The electromagnetic armature is only energized after the rotor is brought up to
near synchronous speed.
Block diagram of a synchronous motor or condenser supplying VAR to keep utility PF constant.
On the figure below the tachometer signal, a pulse train proportional to motor speed, is fed back to a phase
locked loop, which compares the tachometer frequency and phase to a stable reference frequency source such as
a crystal oscillator.
Phase locked loop controls synchronous motor speed.
A motor driven by square waves of current, as provided by simple Hall Effect sensors, is known as a brushless
DC motor. This type of motor has higher ripple torque variation through a shaft revolution than a sine wave
driven motor. This is not a problem for many applications. Though, we are primarily interested in synchronous
motors in this section.
I.5. Special Motors

I.5.1. Stepper Motor
A stepper motor is a “digital” version of the electric motor. The rotor moves in discrete steps as commanded,
rather than rotating continuously like a conventional motor. When stopped but energized, a stepper (short for
stepper motor) holds its load steady with a holding torque. Wide spread acceptance of the stepper motor within
the last two decades was driven by the ascendancy of digital electronics. Modern solid state driver electronics
was a key to its success. And, microprocessors readily interface to stepper motor driver circuits. Application
wise, the predecessor of the stepper motor was the servo motor
Stepper motor vs. servo motor.
Stepper speed characteristics.

I.5.2. Single phase series motor
If a DC series motor equipped with a laminated field is connected to AC, the lagging reactance of the field coil
will considerably reduce the field current. While such a motor will rotate, operation is marginal. While starting,
armature windings connected to commutator segments shorted by the brushes look like shorted transformer
turns to the field. This results in considerable arcing and sparking at the brushes as the armature begins to turn.
This is less of a problem as speed increases, which shares the arcing and sparking between commutator
segments The lagging reactance and arcing brushes are only tolerable in very small uncompensated series AC
motors operated at high speed. Series AC motors smaller than hand drills and kitchen mixers may be
uncompensated.
I.5.3. Compensated series motor
The arcing and sparking is mitigated by placing a compensating winding the stator in series with the armature
positioned so that its magnetomotive force (mmf) cancels out the armature AC mmf. A smaller motor air gap
and fewer field turns reduce lagging reactance in series with the armature improving the power factor. All but
very small AC commutator motors employ compensating windings. Motors as large as those employed in a
kitchen mixer, or larger, use compensated stator windings.
I.5.4.Universal motor
It is possible to design small (under 300 watts) universal motors which run from either DC or AC. Very small
universal motors may be uncompensated. Larger higher speed universal motors use a compensating winding. A
motor will run slower on AC than DC due to the reactance encountered with AC. However, the peaks of the
sine waves saturate the magnetic path reducing total flux below the DC value, increasing the speed of the
“series” motor. Thus, the offsetting effects result in a nearly constant speed from DC to 60 Hz. Small line
operated appliances, such as drills, vacuum cleaners, and mixers, requiring 3000 to 10,000 rpm use universal
motors.
I.5.5. Repulsion motor
A repulsion motor consists of a field directly connected to the AC line voltage and a pair of shorted brushes
offset by 15oto 25o from the field axis. The field induces a current flow into the shorted armature whose
magnetic field opposes that of the field coils. Speed can be controlled by rotating the brushes with respect to
the field axis. This motor has superior commutation below synchronous speed, inferior commutation above
synchronous speed. Low starting current produces high starting torque.
I.5.6. Repulsion start induction motor
When an induction motor drives a hard starting load like a compressor, the high starting torque of the repulsion
motor may be put to use. The induction motor rotor windings are brought out to commutator segments for
starting by a pair of shorted brushes. At near running speed a centrifugal switch shorts out all commutator
segments giving the effect of a squirrel cage rotor. The brushes may also be lifted to prolong bush life. Starting
torque is 300% to 600% of the full speed value as compared to under 200% for a pure induction motor.

I.5.7. Hysteresis motor
If the low hysteresis Si-steel laminated rotor of an induction motor is replaced by a slotless windingless
cylinder of hardened magnet steel, hysteresis, or lagging behind of rotor magnetization, is greatly accentuated.
The resulting low torque synchronous motor develops constant torque from stall to synchronous speed.
Because of the low torque, the hysteresis motor is only available in very small sizes, and is only used for
constant speed applications like clock drives, and formerly, phonograph turntables.
I.5.8.Eddy current clutch
If the stator of an induction motor or a synchronous motor is mounted to rotate independently of the rotor an
eddy current clutch results. The coils are excited with DC and attached to the mechanical load. The squirrel
cage rotor is attached to the driving motor. The drive motor is started with no DC excitation to the clutch. The
DC excitation is adjusted from zero to the desired final value providing a continuously and smoothly variable
torque. The operation of the eddy current clutch is similar to an analog eddy current automotive speedometer.
II. ELECTRIC MOTORS PROTECTION
Motor protection safeguards the motor, the supply system and personnel from various operating conditions of
the driven load, the supply system or the motor itself.
Motor protection categories include

- Overcurrent Protection
- Overload Protection
- Other Types of Protection.
The National Electrical Code requires that motors and their conductors be protected from both overcurrent and
overload conditions.
II.1. Overcurrent Protection
Overcurrent protection interrupts the electrical circuit to the motor upon excessive current demand on the
supply system from either short circuits or ground faults.
• Overcurrent protection is required to protect personnel, the motor branch circuit conductors,
control equipment, and motor from these high currents.
• Overcurrent protection is usually provided in the form of fuses or circuit breakers. These
devices operate when a short circuit, ground fault or an extremely heavy overload occurs.
Most overcurrent sources produce extremely large currents very quickly.
II.2. Overload Protection
Overload protection is installed in the motor circuit and/or motor to protect the motor from damage
from mechanical overload conditions when it is operating/running.
The effect of an overload is an excessive rise in temperature in the motor windings due to current higher than
full load current.

Properly sized overload protection disconnects the motor from the power supply when the heat generated in the
motor circuit or windings approaches a damaging level for any reason. The larger the overload, the more
quickly the temperature will increase to a point that is damaging to the insulation and lubrication of the motor.
Unlike common instantaneous type fuses and breakers, overload devices are designed to allow high currents to
flow briefly in the motor to allow for: Typical motor starting currents of 6 to 8 times normal running current
when starting
Short duration overloads such as a slug of product going through a system. If the motor inlets and outlets are
covered by a blanket of lint or if a bearing should begin to lock, excessive heating of the motor
windings will “overload” the motors insulation which could damage the motor.
The overcurrent device will not react to this low level overload. The motor overload device prevents this type of
problem from severely damaging the motor and also provides protection for the circuit conductors since it is
rated for the same or less current as the conductors. Overload protection trips when an overload exists for more
than a short time. The time it takes for an overload to trip depends on the type of overload device, length of time
the overload exists, and the ambient temperature in which the overloads are located.
II.3. Differential Protection
This protection function is mostly used to protect induction and synchronous motors against phase-to-phase
faults. This function requires two sets of CT’s, one at beginning of the motor feeder, and the other at the star
point. Differential protection may be considered the first line of protection for internal phase to phase or phase
to ground faults. In the event of such faults, the quick response of the differential element may limit the damage
that may have otherwise occurred to the motor.

The differential protection function can only be used if both sides of each stator phase are brought out of the
motor for external connection such that the phase current going into and out of each phase can be measured.
The differential element subtracts the current coming out of each phase from the current going into each phase
and compares the result or difference with the differential pickup level. If this difference is equal to or greater
than the pickup level a trip will occur. GE Multilin motor protective relays support both three and six CT
configurations. For three CT configuration both sides of each of the motors stator phases are being passed
through a single CT. This is known as the core balance method and is the most desirable owing to its sensitivity
and noise immunity.
II.4. Other Motor Protection Devices
II.4.1. Low Voltage Protection
Low Voltage Disconnects - Protection device operates to disconnect the motor when the supply voltage drops
below a preset value. The motor must be manually restarted upon resumption of normal supply voltage. Low
Voltage Release - Protection device interrupts the circuit when the supply voltage drops below a preset value
and re-establishes the circuit when the supply voltage returns to normal.
II.4.2. Medium Voltage Motor Surge Protection
MSP (Motor Surge Protector) is designed to protect medium voltage motors and generators from voltage surges
due to lightning and switching events. The MSP accomplishes this task better than any other product by
decreasing the slope and crest of impending voltage
Application of the MSP is guaranteed to reduce the likelihood of motor failures, resulting in less down-time and
higher productivity.
- Reduced medium voltage motor and generator failures from voltage surges due to lightning, faults, and
switching events.
- Units can be custom designed for direct mounting to generators, motor, and compressor housing.
- Units can be supplied with over-current and differential protection current transformers. Reduced downtime
and material waste from motor failure.

The Principle operation of the MSP is to decrease the crest voltage and rate of rise of the impending surges.
High rates of rise damage end turns while high crest voltages damage winding to core insulation.
Motor Surge Protection Unit with Differential and Phase Overcurrent Current Transformers for Direct
Mounting on Equipment.
II.4.3. Overvoltage
When the motor is running in an overvoltage condition, slip will decrease as it is inversely proportional to the
square of the voltage and efficiency will increase slightly. The power factor will decrease because the current
being drawn by the motor will decrease and temperature rise will decrease because the current has decreased
(based on I2t). As most new motors are designed close to the saturation point , increasing the V/HZ ratio could
cause saturation of air gap flux causing heating.The overall result of an overvoltage condition is an increase in
current and motor heating and a reduction in overall motor performance.
II.4.4. Phase Failure Protection
Interrupts the power in all phases of a three-phase circuit upon failure of any one phase.Normal fusing and
overload protection may not adequately protect a polyphase motor from damaging single phase operation.
Without this protection, the motor will continue to operate if one phase is lost. Large currents can be developed

in the remaining stator circuits which eventually burn out. Phase failure protection is the only effective way to
protect a motor properly from single phasing.
II.4.5. Phase Reversal Protection
Used where running a motor backwards (opposite direction from normal) would cause operational or safety
problems.
Most three phase motors will run the opposite direction by switching the connections of any two of the three
phases. The device interrupts the power to the motor upon detection of a phase reversal in the three phase
supply circuit. This type of protection is used in applications like elevators where it would be damaging or
dangerous for the motor to inadvertently run in reverse.
II.4.6. Ground Fault Protection
Operates when one phase of a motor shorts to ground preventing high currents from damaging the stator
windings and the iron core.
Damage to a phase conductor’s insulation and internal shorts due to moisture within the motor are common
causes of ground faults. A strategy that is typically used to limit the level of the ground fault current is to
connect an impedance between the neutral point of the motor and ground. This impedance can be in the form of
a resistor or grounding transformer sized to ensure that the maximum ground fault current is limited to a level
that will reduce the chances of damage to the motor.
II.4.7. Unbalance Protection
Unbalanced load in the case of AC motors is mainly the result of an unbalance of the power supply voltages.
The negative-sequence reactance of the three-phase motor is 5 to 7 times smaller than positive-sequence
reactance, and even a small unbalance in the power supply will cause high negative sequence currents. For
example for an induction motor with a staring current six times the full load current, a negative sequence
voltage component of 1% corresponds to a negative sequence current component of 6%. The negative-sequence
current induces a field in the rotor, which rotates in the opposite direction to the mechanical direction and
causes additional temperature rise. Main causes of current unbalance are: system voltage distortion and
unbalance, stator turn-to-turn faults, blown fuses, loose connections, as well as faults.
II.4.8. Short Circuit Protection
The short circuit element provides protection for excessively high overcurrent faults. When a motor starts, the
starting current (which is typically 6 times the Full Load Current) has asymmetrical components. These
asymmetrical currents may cause one phase to see as much as 1.7 times the RMS starting current. As a result
the pickup of the short circuit element must be set higher than the maximum asymmetrical starting currents seen
by the phase CTs to avoid nuisance tripping. The breaker or contactor that the relay is to control under such
conditions must have an interrupting capacity equal to or greater then the maximum available fault
II.4.9. Mechanical Jam
The mechanical jam element is designed to operate for running load jams due to worn motor bearings, load
mechanical breakage and driven load process failure. This element is used to disconnect the motor on abnormal
overload conditions before motor stalls. In terms of relay operation, the Mechanical Jam element prevents the

motor from reaching 100% of its thermal capacity while a Mechanical Jam is detected. It helps to avoid
mechanical breakage of the driven load and reduce start inhibit waiting time.
II.4.10. Load Loss Detection
Undercurrent protection is useful for indicating the loss of suction in a pump application, or a broken belt in
conveyor application. The second method of load loss detection is to use of the underpower protection element.
II.4.11.Other Motor Protection Devices
Bearing Temperature Monitors & Protection Winding Temperature Monitors & Protection Devices Current
Differential Relays (Phase Unbalance) Vibration Monitors & Protection
II.4.12.Sizing Motor Overcurrent Protection
Circuit overcurrent protection devices must be sized to protect the branch-circuit conductors and also allow the
motor to start without the circuit opening due to the in-rush current of the motor.
II.4.13.Types of Overcurrent Devices
Selection of the size of the overcurrent protection device is made using NEC Table 430-152 which lists
information for four types of devices:
1) Standard (non-time delay) fuses
2) Time-Delay (dual element) fuses
3) Instantaneous Trip Circuit Breaker
4) Inverse Time Circuit Breaker
II.4.14.Standard Fuse Response

II.4.11.1. Standard (Non-Time Delay, Single Element) Fuses
Standard fuses protect against short circuits and ground faults using thermal features to sense a heat
buildup in the circuit. Once blown standard fuses are no longer usable and must be replaced..
• The NEC allows standard fuses as overcurrent protection devices sized up to a maximum of
300% of the motor’s ratings to allow the motor to start.

An exception allows the use of the next higher size fuse when the table value does not correspond to a standard
size device. An additional exception allows the use of the next size larger device until an adequate size is found
if the motor will not start without operating the device. Standard fuses will hold 500% of their current rating for
approximately one fourth of a second.
NOTE:
Some special standard fuses will hold 500% of their current rating for up to two seconds.
In order for a standard fuse to used as motor overload protection, the motor would have to start and reach its
running speed in one-fourth of a second or less.
Standard fuses will not generally provide any overload protection for hard starting installations because they
must be sized well above 125% of a motor’s FLA to allow the motor to start.
II.4.11.2. Time-Delay (Dual Element) Fuses
These are generally dual element fuses with both thermal and instantaneous trip features that allow the motor
starting current to flow for a short time without blowing the fuse.
Time delay fuses can also be used to provide some degree of overload protection which standard fuses cannot.
The NEC allows time delay fuses to be sized up to a maximum of 175% of a motor’s FLA for overcurrent
protection. Time-delay fuses will hold 500% of their amp rating for 10 seconds which will allow most motors to
start without opening the circuit. Under normal conditions, a 100-amp time-delay fuse will start any motor with
a locked-rotor current rating of 500 amps or less.
II.5. Circuit Breakers

II.5.1. Inverse CB Trip Curve
Inverse time circuit breakers have both thermal and instantaneous trip features and are preset to trip
at standardized levels. This is the most common type of circuit breaker used in the building trades for
residential, commercial, and heavy construction. The thermal action of this circuit breaker responds to heat.
If a motor’s ventilation inlets and outlets are not adequate to dissipate heat from the windings of the motor, the
heat will be detected by the thermal action of the circuit breaker.
If a short should occur, the magnetic action of the circuit breaker will detect the instantaneous values of current
and trip the circuit breaker.
The National Electrical Code requires inverse time circuit breakers to be sized to a maximum of 250%
of the motor FLA.
The rating of an inverse time circuit breaker can be multiplied by 3 and this total amperage will start any
motor with less locked-rotor amperage. The time it takes to reach the 300% level varies with the amperage and
voltage ratings of the breaker as shown in the curve.
II.5.2. Instantaneous Trip Circuit Breakers
Instantaneous trip circuit breakers respond to immediate (almost instantaneous) values of current from a short
circuit, ground fault, or locked rotor current. This type of circuit breaker will never trip from a slow heat
buildup due to motor windings overheating. A stuck bearing or a blanket of lint covering the inlets and outlets
of the motor’s enclosure will cause the motor to overheat and damage the windings.
• The National Electrical Code allows instantaneous trip circuit breakers to be sized to a maximum of 800% of a
motors FLA value.
• They are used where time-delay fuses set at five times their ratings or circuit breakers at three times their
rating will not hold the starting current of a motor. Some instantaneous trip circuit breakers have adjustable trip
settings. The instantaneous trip ratings of an instantaneous trip circuit breaker can be adjusted above the locked-
rotor current of a motor to allow the motor to start and come up to its running speed.
II.6. Motor Overload Protection
Motors larger than 1 horsepower must be provided separate motor overload protection devices.
The most common devices typically used include:
1) Magnetic or thermal overload devices
2) Electronic overload relays
3) Fuses
II.6.1. Magnetic & Thermal Overloads
Overload devices are usually located in the motor’s starter and connected in series with the motors electrical
supply circuit and can be operated by either magnetic or thermal action. The same amount of current passes
through the overload relay and the motor. If the current or heat through the overload device is higher than the
device’s rating, it trips and shuts down the electric power to the motor.
II.6.2. Magnetic Overload Relays
A magnetic overload relay is an electro-mechanical relay operated by the current flow in a circuit.
.
When the level of current in the circuit reaches a preset value, the increased magnetic field opens a set of
contacts. Electromagnetic overload relays operate on the magnetic action of the load current flowing through a
coil
When the load current becomes too high, a plunger is pulled up into the coil interrupting the circuit. The
tripping current is adjusted by altering the initial position of the plunger with respect to the coil.
II.6.3. Thermal Overload Relays
A thermal overload relay is an electro-mechanical relay that is operated by heat developed in the
relay. When the level of current in a circuit reaches a preset value, the increased temperature opens a set of
contacts. The increased temperature opens the contacts through a bimetallic strip or by melting an alloy that
activates a mechanism that opens the contacts. Two types include melting alloy and the bi-metallic strip.

II.6.3.1. Melting-Alloy Thermal Overload Relays
These are probably the most popular type of overload protection.
The motor current passes through a small heater winding and under overload conditions, the heat causes a
special solder to melt allowing a ratchet wheel to spin thus opening the control circuit contacts.
- Must be reset by hand operation
-Heater coil and solder pot in one unit non-tamperable
II.6.3.2. Bimetallic Thermal Overload Relays
This design uses a bimetal strip associated with a current-carrying heater coil. When an overload occurs, the
heat causes the bimetal to deflect and actuate a tripping mechanism which opens a set of contacts in the control
circuit interrupting power to the coil and opening the power contacts.
Most relays are adjustable over a range from 85% to 115% of their value. They are available with ambient
compensation. An ambient compensated devices’ trip point is not affected by ambient temperature and performs
consistently at the same value of current.
II.6.3.3. Automatic Reset Devices
Automatic reset is an advantage where the starter is inaccessible and the motor is provided three
wire control from a magnetic starter.
This control doesn’t allow the motor to restart until the start push button is manually pushed. This permits the
overload condition to be removed before the motor restarts.

II.6.4.Electronic Overloads
Electronic overloads sense the load current and the heating effect on the motor is computed. If an
overload condition exists, the sensing circuit interrupts the power circuit. The tripping current can be adjusted to
suit the particular application. Electronic overloads often perform additional protective functions such as ground
fault and phase loss protection.
II.6.5. Fuses
Fuses have limited application as the primary means of overload protection for motors but can be effectively
used to provide back up overload protection.
Single-element fuses are not designed to provide overload protection. Their basic function is to protect against
short circuits and ground faults. If sized to provide overload protection, they would blow when the motor starts
due to high motor inrush current. Dual-element fuses can provide motor overload protection, but they have to be
replaced when they blow which can be a disadvantage.
There is a risk of single-phasing damage to the motor when only one fuse blows unless Single-phase protection
is provided.
II.6.6.Overload Trip Time
The time it takes an overload to trip depends on the length of time the overload current exists.
A Heater Trip Characteristics chart shows the relationship between the time an overload takes to trip and the
current flowing in the circuit based on the standard 40EC ambient temperature installation.

The larger the overload (horizontal axis), the shorter the time required to trip the overload (vertical axis).
Any change from ambient temperature affects the tripping time of an overload.
For temperatures higher than 40EC, the overloads trip at a current rating less than the value of the overload.
II.6.7. Sizing Motor Overload Protection
There are several types of devices that can be used to provide overload protection and the sizing
procedure can vary depending on the type of device used.
It is important to keep differences in the procedures separate and understood well so as not to install overloads
that do not provide adequate protection to the motor. The simplest and most straightforward sizing procedures
for motor overload protection are applied when sizing overload relays using the cover of the motor starter,
control center, or manufacturer’s catalog.
The National Electrical Code specifies methods to calculate the maximum size motor overload protection for
specific motors if a manufacturer’s chart is not available. Installations relying on fuses and circuit breakers as
back-up overload protection must be calculated using the NEC method.
For motors rated 40EC with a Service Factor of 1.15 or greater, 125% of the motors FLA is used to calculate
the maximum size device for overload protection.
The size overloads required to protect the windings of a motor can be determined by taking the motor’s full-
load current rating and selecting the size overloads from the cover of a magnetic starter,
a motor control center, or the manufacturer’s catalog. The following things should be kept in mind when using
manufacturer’s charts. When the overload size is selected from the cover of a magnetic starter or controller, the
nameplate full-load running current of the motor is used. The full-load running current is
II.6.8. Ambient Temperature Compensation
The ambient temperature in which a starter and motor is located must be considered when selecting overloads
because a high ambient temperature reduces overload trip time.
Reduced overload trip time can lead to nuisance tripping if a motor is located in a cooler ambient temperature
than the starter and lead to motor burnout when the motor is located in a hotter ambient temperature than the
starter. Most thermal overload devices are rated for use at a maximum temperature of 40 degrees C which is
about 104 degrees F.
The overload device trips at less than 100 percent rated current when the ambient temperature exceeds 104
degrees F which can result in “nuisance tripping”.
If the temperature is significantly below 104 degrees F, the overload device allows significantly more current
through than it is rated for resulting in potential motor overload and failure without the overload tripping the
motor off.
A higher overload heater can be selected when the ambient temperature at the starter is higher than the
temperature at the motor and a lower value selected when the ambient temperature at the starter is lower than
the temperature at the motor.
If the temperature varies widely during the year, the motor may not be protected when the temperature swings
dramatically the other way unless the original overloads are switched back.
II.6.8.1. Ambient Compensated Heaters
For this reason, special Ambient Compensated Heaters which have a much “flatter” temperature response
should be used in most outdoor applications and where ambient operating temperatures are significantly
different.
II.7. Sizing Motor Protection Systems
Given the following motor, size the conductors, motor overcurrent and motor overloads to adequately protect
the motor and conductors.
Nameplate Info: FLA = 22 Service Factor = 1.00 Ambient = 40 C
STEP 1: Determine the motor’s FLA (full load amps)

STEP 2: Determine the size of branch circuit conductor required.
NEC 430-22 says the conductor ampacity equals the FLA x 125%
- Conductors supplying a single motor used for a continuous duty load must have a current
carrying capacity of not less than 125% of the motor’s full load current (FLA) rating
- Conductor Ampacity = 28 amps X 1.25 = 35 amps
STEP 3: Determine the branch circuit overcurrent device size.
The maximum branch circuit overcurrent device size is calculated based on the type of protective
device selected (standard fuse, time-delay fuse, instantaneous breaker, inverse time breaker) and percentage
multiplier from according to the standards.
Multiply the motors design FLA by the appropriate percentage in NEC Table 430-152.
1. When the value found does not match a standard fuse/breaker size the NEC permits the
next higher STANDARD size for a branch circuit overcurrent device.
STEP 4: Determine the required size for the motor running overload protection.
1. Use the nameplate FLA directly to find the appropriate overload device heater on the motor
starter cover or from manufacturers tables.
2. Use the nameplate FLA and NEC Section 430-32 to calculate the maximum size
for the motor overload protection in amps.
III.ELECTRIC MOTORS INSTALLATION

III.1. General Guidelines to electrical Motors Installations
A strong working knowledge of installation techniques is vital to the effective operation and maintenance of
motors.
Today's modern motors require your consideration of all aspects of selection, application, and maintenance as
well as details of assembly, hardware, and the interrelationship of components and materials. As a result,
installation of these motors is more important than ever before.
Proper motor installation is essential in obtaining top-quality operation, efficient performance, and maximum
reliability. Whether you're an installer, engineer, or maintainer, this work demands close coordination, planning,
and teamwork with other disciplines. Rolling-element bearings used in electric motors potentially have many
failure modes if an incorrect strategy is implemented. These modes include incorrect lubricant selection,
contamination, loss of lubricant and overgreasing. This article will discuss several effective strategies to
minimize the likelihood of these failure modes.
Most electric motors are designed with grease-lubricated, anti-friction, rolling-element bearings. Grease is the
lifeblood of these bearings, providing an oil film that prevents harsh metal-to-metal contact between the rotating
element and races.
III.2. Motor Start and Speed control
Most AC motors are induction motors. Induction motors are favored due to their ruggedness and simplicity. In
fact, 90% of industrial motors are induction motors.
Autotransformer induction motor starter
Nikola Tesla conceived the basic principals of the polyphase induction motor in 1883, and had a half
horsepower (400 watts) model by 1888. Tesla sold the manufacturing rights to George Westinghouse for
$65,000.
Most large (> 1 hp or 1 kW) industrial motors are poly-phase induction motors. By poly-phase, we mean that
the stator contains multiple distinct windings per motor pole, driven by corresponding time shifted sine waves.
In practice, this is two or three phases. Large industrial motors are 3-phase. While we include numerous
illustrations of two-phase motors for simplicity, we must emphasize that nearly all poly-phase motors are three-
phase. By induction motor, we mean that the stator windings induce a current flow in the rotor conductors, like
a transformer, unlike a brushed DC commutator motor.
III.3. Running 3-phase motors on 1-phase
Three-phase motors will run on single phase as readily as single phase motors. The only problem for either
motor is starting. Sometimes 3-phase motors are purchased for use on single phase if three-phase provisioning
is anticipated. The power rating needs to be 50% larger than for a comparable single phase motor to make up
for one unused winding. Single phase is applied to a pair of windings simultaneous with a start capacitor in
series with the third winding. The start switch is opened in Figure below upon motor start. Sometimes a smaller
capacitor than the start capacitor is retained while running.
Three phase power may be tapped off from the three stator windings for powering other 3-phase equipment.
The capacitor supplies a synthetic phase approximately midway ∠90o between the ∠180o single phase power
source terminals for
starting. While running, the motor generates approximately standard 3-φ, as shown in Figure above.
III.4. Self-starting static phase converter Run capacitor
Since a static phase converter has no torque load, it may be started with a capacitor considerably smaller than a
normal start capacitor. If it is small enough, it may be left in circuit as a run-capacitor. See Figure above.
However, smaller run-capacitors result in better 3-phase power output as in Figure below. Moreover,
adjustment of these capacitors to equalize the currents as measured in the three phases results in the most
efficient machine.
III.5. More efficient static phase converter Start capacitor
However, a large start capacitor is required for about a second to quickly start the converter The above fig
shows construction details.
III.6. Electronic variable speed drive
Modern solid state electronics increase the options for speed control. By changing the 50 or 60 Hz line
frequency to higher or lower values, the synchronous speed of the motor may be changed. However, decreasing
the frequency of the current fed to the motor also decreases reactance XL which increases the stator current.
This may cause the stator magnetic circuit to saturate with disastrous results. In practice, the voltage to the
motor needs to be decreased when frequency is decreased.

Conversely, the drive frequency may be increased to increase the synchronous speed of the motor. However,
the voltage needs to be increased to overcome increasing reactance to keep current up to a normal value and
maintain torque. The inverter (Figure) approximates sinewaves to the motor with pulse width modulation
outputs. This is a chopped waveform which is either on or off, high or low; the percentage of “on” time
corresponds to the instantaneous sine wave voltage.
III.7. Stepping a Permanent magnet stepper Motor
Permanent magnet stepper motors require phased alternating currents applied to the two (or more) windings. In
practice, this is almost always square waves generated from DC by solid state electronics. Bipolar drive is
square waves alternating between (+) and (-) polarities, say, +2.5 V to -2.5 V. Unipolar drive supplies a (+) and
(-) alternating magnetic flux to the coils developed from a pair of positive square waves applied to opposite
ends of a center tapped coil. The timing of the bipolar or unipolar wave is wave drive, full step, or half step
Wave drive. The wave drive waveforms below show that only one coil is energized at a time. While simple, this
does not produce as much torque as other drive techniques.
Waveforms: bipolar wave drive.
III.8. Samples on Installation of DC Motors

III.8.1. Shunt wound Motors
are the most widely used as they have a linear characteristic of Voltage & Torque. Shunt motor has more
constant and controllable speed over various loads.
This type of motor runs practically constant speed, regardless of the load. It is the type generally used in
commercial practice and is usually recommended where starting conditions are not usually severs

III.8.2. Series Wound Motors
Series Wound Motor is used for High starting Torque Applications. Series motor has greater torque capabilities.
This type of motor speed varies automatically with the load, increasing as the load decreases. Use of series
motor is generally limited to case where a heavy power demand is necessary to bring the machine up to speed,
as in the case of certain elevator and hoist installations, for steelcars, etc. Series-wound motors should never be
used where the motor can be started without load, since they will race to a dangerous degree.
Common uses of the series motor include crane hoists, where large heavy loads will be raised and lowered and
bridge and trolley drives on large overhead cranes.
III.8.3. Compound Wound Motors
Compound Wound Motors are used for Mixed Load Applications. The above two desirable characteristics can
be found in the same motor by placing both a Series field and Shunt field winding on the same pole. Thus we
have, the Compound motor. The Compound motor responds better to heavy load changes than a Shunt motor
because of the increased current through the series field coils. This boosts the field strength, providing added
torque and speed.
A combination of the shunt wound and series wound types combines the characteristics of both. Characteristics
may be varied by varying the combination of the two windings

III.9. Sample on installation of Induction Motors
III.9.1. Installation of Single phase Capacitor run-Capacitor start Motor
Above circuit is the simplest of all and acts just like an electro-mechanical reversing switch. The following
circuits show the internal configuration and capacitor/split-phase connections
III.9.2. Star-delta starters with overload relay

Arrangement in the motor line
In a standard circuit configuration, the star-delta starter with
overload relay, including a thermally delayed overcurrent relay are
situated in the cables leading to the motor terminals U1, V1, W1 or
V2, W2, U2. The overload relay can also be operated in a star
circuit as it is usually connected in series with the motor winding
and the relay current flowing through it = rated motor current
× 0.58.

Arrangement in the mains supply line

Instead of the arrangement in the motor line, the overload relay can
be placed in the mains supply line. For drives where the F2 relay
trips out when the motor is starting in the star circuit, the F2 relay
rated for the rated motor current can be switched in the mains
line. The tripping delay is thus increased by approximately four to
six times. In the star circuit the current also flows through the relay
but here the relay does not offer full protection since its limit
current is increased to 1.73 times the phase current. It does,
however, offer protection against non-starting.

Configuration in the delta circuit
Instead of the arrangement in the motor line or mains supply line,

the overload relay can be placed in the delta circuit. When heavy,
long-starting procedures are involved (e.g. for centrifuges) the F2
relay, rated for relay current = rated motor current × 0.58, can also
be connected in the connecting lines between delta contactor Q15
and star contactor Q13. In the star circuit no current then flows
through relay F2. This circuit is used wherever exceptionally
heavy and long starting procedures are involved and when
saturable core current transformer-operated relays react too quickly
III.10. Visual and Mechanical inspections
Accepted good practice is to keep the difference in voltage between the point at which power is and the motor
terminals below 3 percent when the motor is delivering full load delivered from the utility.
An important aspect of large machine maintenance is the visual and mechanical inspection.
1. Inspect the machine's physical and mechanical condition.

 Check for signs of oil or water leakage. Check the water and oil supply piping.
 Verify that air inlets are not plugged and abnormal sound or smells
 Check the water and oil supply piping.
 Check the drain piping and the surroundings for any environmental issues that may affect performance.
2. Inspect anchorage, alignment and grounding of the motor, driven equipment and base.
3. Verify the application of appropriate lubrication and lubrication systems.
4. Verify the absence of unusual mechanical or electrical noise or signs of overheating.
5. Perform special tests such as air-gap spacing and machine alignment, if applicable
III.11. Possible relevant standards
Standard n° Title What it covers

NEMA MG 1-2.02 Motors and Generators Assists users in the proper selection and application of
motors and generators.
NEMA MG 1-2.05 Energy Management Guide for Provides practical information concerning proper
Selection and Use of fixed selection and application of polyphase induction and
Frequency Medium AC Squirrel- synchronous motors, including installation, operation
Cage Polyphase Induction Motors. and maintenance.
ANSI/NETA MTS- Standard for Maintenance Testing

2007 Specifications for Electrical
Distribution Equipment and
Systems.
IV. CONCLUSION
Selecting the appropriate protection and full requirements for electric motors installation based on Standards,
optimize the system efficiency and performance also allow the users to be safe and bring to the long life of the
machine, as intent of a good maintenance program is to extend the service life of your motors.
V. REFERENCES
1. T.Cox Lloyd, Electric Motors and their Applivation, 1969
2. Electric Motor Control and Maintenance, www.abb.com/powergeneration
3. Blahut, R. E., “Principles and Practice of Electrical installations,” Addison-Wesley, 1987.
4. Cover, T. M., and J. A. Thomas, “Elements of Electrical Machines,” Wiley, 1991.

5. Gallagher, R., “Information Theory and Reliable Electric protection,” Wiley, 1968.
6. Widup, R., Large Motor Maintenance: Basics for machine reliability. 2008.


Eric Assignm

Загружено:

Сведения о документе

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Eric Assignm

Загружено:

Авторское право:

Доступные форматы

I. INTRODUCTION TO ELECTRIC MOTORS...............................................................................................

Page 1 of 27 Industrial Safety and Maintenance

Page 2 of 27 Industrial Safety and Maintenance

I.1. Single phase induction Motor

I.2. Wound rotor induction Motor

I.3. Capacitor-start induction motor

I.4. Synchronous motor

Page 3 of 27 Industrial Safety and Maintenance

I.4.2. Three-phases phase Synchronous motor

The number of poles is n. For rotor speed in rpm, multiply by 60.

Phase locked loop controls synchronous motor speed.

I.5. Special Motors

Stepper motor vs. servo motor.

Stepper speed characteristics.

Page 5 of 27 Industrial Safety and Maintenance

I.5.3. Compensated series motor

I.5.5. Repulsion motor

I.5.6. Repulsion start induction motor

Page 6 of 27 Industrial Safety and Maintenance

I.5.8.Eddy current clutch

II. ELECTRIC MOTORS PROTECTION

Motor protection categories include

II.1. Overcurrent Protection

II.2. Overload Protection

Page 7 of 27 Industrial Safety and Maintenance

II.3. Differential Protection

Page 8 of 27 Industrial Safety and Maintenance

II.4. Other Motor Protection Devices

II.4.1. Low Voltage Protection

II.4.2. Medium Voltage Motor Surge Protection

Page 9 of 27 Industrial Safety and Maintenance

II.4.4. Phase Failure Protection

Page 10 of 27 Industrial Safety and Maintenance

II.4.5. Phase Reversal Protection

II.4.6. Ground Fault Protection

II.4.7. Unbalance Protection

II.4.9. Mechanical Jam

Page 11 of 27 Industrial Safety and Maintenance

II.4.10. Load Loss Detection

II.4.11.Other Motor Protection Devices

II.4.12.Sizing Motor Overcurrent Protection

II.4.13.Types of Overcurrent Devices

II.4.14.Standard Fuse Response

Page 12 of 27 Industrial Safety and Maintenance

II.4.11.2. Time-Delay (Dual Element) Fuses

II.5. Circuit Breakers

Page 13 of 27 Industrial Safety and Maintenance

II.5.2. Instantaneous Trip Circuit Breakers

II.6. Motor Overload Protection

II.6.1. Magnetic & Thermal Overloads

II.6.2. Magnetic Overload Relays

II.6.3. Thermal Overload Relays

Page 15 of 27 Industrial Safety and Maintenance

These are probably the most popular type of overload protection.

II.6.3.2. Bimetallic Thermal Overload Relays

II.6.3.3. Automatic Reset Devices

Page 16 of 27 Industrial Safety and Maintenance

II.6.6.Overload Trip Time

Page 17 of 27 Industrial Safety and Maintenance

II.6.7. Sizing Motor Overload Protection

II.6.8. Ambient Temperature Compensation

II.6.8.1. Ambient Compensated Heaters

II.7. Sizing Motor Protection Systems

STEP 1: Determine the motor’s FLA (full load amps)