Types of circuit breaker:
MCBs (Miniature Circuit Breakers) are categorized into B, C and D types. These three ratings
are determined by the level of overload, which causes the MCB to trip.
1. B type MCBs operate at an overload of 3 to 5 times the rated current. Type B MCBs are
usually used in domestic installations where the inrush currents and surges are low.
2. C type MCBs operate at an overload of 5 to 10 times the rated current. These MCBs are
used in commercial and industrial installations where high inrush current are likely due to
motor starting or due to large no of fluorescent lighting.
3. D type MCBs are used in special applications such as x-ray machines and transformers,
which can draw heavy inrush current.
Types of contactor:
AC1 - These type of contactors are used for Non-inductive or slightly inductive loads. They
are used for Heaters, which are resistive loads.
AC2 - These type of contactors are used in Starting of slip-ring motors
AC3 - They are particularly used for Starting of squirrel-cage motors and switching off only
after the motor is up to speed.
AC4 - Starting of squirrel-cage motors with inching and plugging duty. Rapid Start/Stop.
AC11 - Auxiliary (control) circuits i.e. they do not have power contacts.
AC-6a- Switching of Transformers.
AC-6b- Switching of Capacitor banks.
Selection of Circuit breaker:
The maximum operating voltage of the circuit breaker is greater than the motor nominal
voltage.
The short circuit current does not exceed the circuit breaker breaking capacity (Icu).
The inrush current does not exceed the magnetic tripping current.
The motors nominal current is within the thermal trip setting range of the overload
protection system.
Selection of Contactor:
The panel temperature acceptable by the selected contactor must be compatible with the
project data.
The maximum voltage (Ue) that can be withstood by each pole of the contactor must be
greater than motor working voltage (Un).
The maximum current that can be withstand by each pole of the contactor must be greater
than the Rated load amperage of the motor.
The Rated making capacity (RMC) & Rated breaking capacity (RBC) of the contactor must
be greater than the maximum starting current of the motor. (multiple of motors nominal
current (A): Coef.6)
Check that the starting current value & maximum starting time are compatible with the
contactors thermal constraint.
For short times, a contactor can be used above its design current, provided one check that:
The current does not exceed the maximum permissible current for the given
operating time
The minimum interval between two cycles is complied with.
What does the Trip Class 10, Class 20, and Class 30 mean for overload
relays?
That at 600% of the maximum thermal unit current rating or 600% of the actual dial setting
on adjustable range OLR`s the Class 10 will trip in 10 seconds or less, Class 20 will trip in 20
seconds or less, and Class 30 will trip in 30 seconds or less.
Heat Transfer Load Calculations for Enclosure:
Total heat load = Internal Heat Load + Heat transfer load
1 Watt = 3.413 BTU/Hr.
Methods to determine Internal Heat Load
1. Data from Each Electronics Component- Customer may know amount of heat their
equipment is generating
2. Component Power Component Efficiency (Utilize component efficiency to estimate
heat load) e.g. System uses two components that draw 115 VAC at 15 amps. Each has a
rated efficiency of 90% (10% of each device becomes heat).
INTERNAL HEAT LOAD = COMPONENT POWER (W) - COMPONENT EFFICIENCY Estimated
internal heat load is
Device Power = 115 x 15 = 1725 W
Total Power = 2 x 1725 = 3450 Less Efficiency = 3450 x (1 - .90)
Total Heat Load = 345 W
3. Incoming Outgoing Power (Utilize power input and output to estimate heat load)
E.g., an enclosure has three input lines of 230 VAC at 11, 6 and 4 A. It has one output
control line of 115 VAC at 9 A.
INTERNAL HEAT LOAD = INCOMING POWER (W) OUTGOING POWER (W)
Estimated internal heat load is
Incoming Power = (230 x 11) + (230 x 6) + (230 x 4) = 4830 W
Outgoing Power = 115 x 9 = 1035 W
Total Heat Load = 4830 1035 = 3795 W
4. Automated Equipment Horsepower (Utilize horsepower (hp) to estimate heat load)
E.g. A cabinet has three 5-hp VFDs with 95% efficiency 1 hp = 745.6 W
Estimated internal heat load is: VFD Watts = 5 hp x 745.6 x 3 = 11184
Adjusted Watts = 11184 x (1 - .95) = 559
Total Heat Load = 559 x 1.25 = 699 W
1.25 is an assumed safety margin for other minor heat producing components.
DETERMINE HEAT TRANSFER LOAD-
METHODS TO DETERMINE HEAT TRANSFER LOAD
1. Simple Chart Method (Reasonably accurate for most indoor industrial systems)
Step A. Determine T in F or C
Step B. Find the heat transfer per ft.2 or m2 on the chart, using T and the proper
enclosure material curve.
Step C. Multiply the heat transfer per ft.2 or m2 by the total surface area of the
enclosure that will conduct heat. (Remember to exclude surfaces such as a side mounted
to a wall.)
2. Equation Method
The governing equations for heat transfer load are:
English System (F, inches and feet): q = (To - Ti) [(1/ho) + (1/hi) + R]
Metric System (C, millimetres and meters): q = (To - Ti) [(1/ho) + (1/hi) + R] x 5.67 q =
(125 - 75) [(1/6) + (1/2) + 4] q = (50) (.16 + .5 + 4) q = 50 4.66 q = 10.7 BTU/hr./ft.2
Total Heat Transfer Load 10.7 x 72 = 770 BTU/hr. or 770 3.413 = 226 W
Since the cabinet is outdoors, and assuming it is painted ANSI 61 gray and located in the
sun, extra solar load needs to be added to the outcome above which is 504 Watts (7 W
per ft.2 x 72 ft.2).
Total Heat Transfer Load with Extra from Solar Heat Gain 226 + 504 = 730 WA
DETERMINE TOTAL HEAT LOAD
Total Heat Load = INTERNAL HEAT LOAD + HEAT TRANSFER LOAD
E.g., the internal heat load from one of the earlier examples was 3795 Watts. If the heat
transfer load is 730 W.
Total Heat Load = 3795 + 730 = 4525 W.
AIR CONDITIONER SPEC EXAMPLE Estimated internal heat load:
Device Power = 115V x 17Amp = 1955 W
Total Power = 6 x 1955W = 11730W
Less Efficiency = 11730W x (1 - .90)
Total Heat Load = 1173 W
Online Product Selection Tool:
Total heat load = 1733 W BTU/Hr. = 1733 x 3.413 = 5914
Types of starter:
Stator Resistance Starter -
In this method, a reduced voltage is applied to the induction motor by connecting external
resistances in series with each phase of the stator winding.
During the motor start, these resistances are kept at maximum position such that a reduced voltage
is applied across the motor due to large voltage drop across resistances. The schematic diagram for
this type of starter is shown in figure below.
Once the motor picks up the speed, the resistance connected to each phase is gradually reduced
from the stator circuit. When these resistances are removed from the circuit, a rated voltage (full
voltage) is applied to the motor and hence it runs at rated speed.
In this method, it is important to maintain the starting torque to the motor while minimising the
starting current. This is because current varies in proportion to the voltage whereas the torque
varies square of the applied voltage.
Suppose if the applied voltage is reduced by 50 percent, the current will be reduced to 50 percent
while the torque reduced by 25 percent.
The construction of this starter is simple and it is the most economical method than all methods.
Also, this starter can be used for motor whether they are a star or delta connected. However, due to
high power dissipation in the resistors, a large power loss takes place in the motor.
In addition, a reduced voltage causes a reduced torque at start of the motor. Due to these
limitations, resistance method is limited for some applications.
Auto Transformer Starter -
In this method, a three-phase autotransformer is connected in series with the motor. This
transformer reduces the voltage applied to the motor and hence the current. The schematic diagram
for this type of starter is shown in figure below.
This starter consists of changeover switch that switches the motor between reduced voltage and full
voltage conditions. When this switch is in the start position, a reduced voltage is applied to the
motor.
This voltage depends on the fractional percentage of tapings and is controlled by changing the
position of autotransformer slider.
When the motor attains 80 percent of its rated speed, the changeover switch is connected to RUN
position automatically using relays. Due to this, a rated voltage is then applied to this motor. These
transformers are, also provided with overload, no-load and time delay circuits.
In this method, the motor terminal voltage is higher for a given starting current on the line side as
compared to other reduced voltage methods. Therefore, this method gives highest starting torque
per line ampere current.
This stator can be connected to both star and delta connected three phase motors. However, these
starters are more expensive than stator resistance starter
Star Delta Starter -
It is the most commonly used reduced voltage starter, as it is the cheapest starter among all. In this
method, induction motor is connected in star during start and delta while running with rated speeds.
These starters are designed to run on delta-connected stator of an induction motor. The schematic
diagram of this starter is shown in figure below.
This starter uses a TPDT (triple pole double throw) switch and it connects the stator winding in star
during the starting condition. Due to this star connection, the applied voltage to the motor is
reduced by the factor 1/3. This reduced voltage results the less current through the motor.
When the motor picks up the speed, the TPST switch is thrown automatically on the other side by
using relays such that the winding is now connected in delta across the supply. So the normal
voltage is applied to the motor (because in delta connection voltage is same, VL =VP) and hence the
motor runs at normal speed.
This method is cheap and maintenance free as compared to other methods. However, this is suitable
only for delta-connected motors and the factor by which starting voltage reduced, i.e., 1/3 cannot
be altered.
Direct on-line starter -
As discussed earlier that small capacity motors (below 5 HP) does not have very high starting
currents. And without using any starter, such motors can withstand the starting currents.
There is no need to reduce the voltage to the motor at start and hence motor can be connected
directly to the supply lines. This type of arrangement employed in a starter is referred as direct on-
line starter or simply DOL starter.
Although, this starter does not reduce the starting voltage, it provides the protection to the motor
against overloading, single phasing and low voltage. The schematic diagram of direct online starter is
shown in figure below.
During start condition, normally open contact (NO) is pushed for fraction of a second and this makes
the magnetising coil becomes energised. This magnetic flux produced by the coil attracts the
contactor so that the motor is now connected to the supply.
The contactor maintains this position while the coil gets supply from the additional switch. When a
normally closed (NC) switch is pressed, the coil becomes de-energised and the contactor get
separated by spring arrangement there by the supply to the motor is removed.
Under any overload condition, motor draws a heavy current that causes overheating. This excessive
heating operates the thermal relays using overload sensors. Overload contacts then operates to
remove the supply to the motor.
It is the simplest, cheapest and most reliable method and hence widely used. The main disadvantage
of DOL starter is that the motor draws a very high current during start for a short period.
Soft starter -
In this method, semiconductor power switches are employed for reducing the starting current to the
induction motor. It is another type of reduced voltage starter and it connected in series with the line
voltage applied to the motor. The schematic diagram of soft starter is shown in figure below
This starter consists of back-to-back thyristors or TRIACs in each phase of the stator winding. By
controlling the firing angle to these thyristors, the voltage applied to the motor will be reduced
steplessly. This type of voltage reduction gives a smoother operation as compared to other methods
discussed above.
This results the absence of torque pulsations and hence there no jerking when starting of the motor.
Once the motor gets the normal speed, the firing angle to the thyristors is applied such that they
allow full voltage to the motor.
For larger motors, a variable frequency drives are used that incorporates the soft start function. Such
drives control the starting current as well as the speed of the motor to a desired value.
These starters are also provided with additional protections, such as overload, low voltage and single
phasing.