EEX10303 Designing LV Motor Circuit

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
Designing Low Voltage

AC Induction Motor Circuits
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s
employees. Any material contained in this document which is not
already in the public domain may not be copied, reproduced, sold, given,
or disclosed to third parties, or otherwise used in whole, or in part,
without the written permission of the Vice President, Engineering
Services, Saudi Aramco.
Chapter : Electrical For additional information on this subject, contact

File Reference: EEX10303 W.A. Roussel on 874-1320
Engineering Encyclopedia Electrical
CONTENTS PAGES
MOTOR STARTER CONTROL CIRCUITS ................................................................ 1

Introduction .............................................................................................................. 1
Control Circuit Components..................................................................................... 2
Pushbuttons ........................................................................................................ 3
Selector Switches................................................................................................ 7
Indicating Lights............................................................................................... 10
Control Relays .................................................................................................. 13
Control Power Transformers (CPT) ................................................................. 15
Wiring............................................................................................................... 17
Contactor .......................................................................................................... 18
Circuit Breaker or MCP.................................................................................... 21
Overload (O/L) Relay....................................................................................... 22
Control Logic Description: Manual Starter ........................................................... 23
Toggling ........................................................................................................... 23
Pushbutton ........................................................................................................ 24
Mechanical Tripping ........................................................................................ 25
Reset ................................................................................................................. 25
Control Logic Description: Non-Reversing Starter ............................................... 26
Three-Point....................................................................................................... 26
Two-Point (Hand-Off-Auto)............................................................................. 28
Overload Relay Contacts .................................................................................. 30
Run and Stop Indicator (Pilot) Lights............................................................... 30
Control Logic Description: Reversing Starter ....................................................... 30
Full-Speed Reversing (Small Size Motors) ...................................................... 31
Stop Before Reversing (Medium Size Motors) ................................................ 32
Time-Out Before Reversing (Large Size Motors) ............................................ 34
Mechanical and Electrical Interlocks................................................................ 34
Control Logic Description: Reduced-Voltage Wye-Delta Starter ......................... 35
Mechanical and Electrical Interlocks................................................................ 36
Transition Timer ............................................................................................... 37
Control Logic Description: Circuit Breaker Starter............................................... 37
MOTOR PROTECTION REQUIREMENTS .............................................................. 41
Introduction ............................................................................................................ 41
Motor T/C Characteristic Curves ........................................................................... 41
Thermal Capability Curve ................................................................................ 41
Motor Starting Curve........................................................................................ 41

Thermal Protection................................................................................................. 43
Thermal Overload (O/L) Protection ................................................................. 43
Thermal Locked-Rotor (L/R) Protection .......................................................... 44
Fault Protection ...................................................................................................... 44
Phase Faults...................................................................................................... 44
Ground Faults (Greater Than 30 Horsepower) ................................................. 47
Undervoltage Relay Protection (Greater Than 100 Horsepower) .......................... 50
Protection Scheme One-Line Diagrams ................................................................. 51
Horsepower Categories of Protection............................................................... 51
SELECTING LOW VOLTAGE COMBINATION MOTOR STARTERS.................. 55
Introduction ............................................................................................................ 55
Motor Starter Components ..................................................................................... 55
Overload (O/L) Protection................................................................................ 55
Controller.......................................................................................................... 58
Fault Protection ................................................................................................ 59
Disconnect ........................................................................................................ 60
Enclosure .......................................................................................................... 61
NEMA Enclosure Classification System................................................................ 61
NEMA Types.................................................................................................... 61
Common Enclosure Components ..................................................................... 65
Enclosed Type Starters ..................................................................................... 67
Saudi Aramco Applications.............................................................................. 72
Overload Relay (O/L) Selection Factors ................................................................ 72
Motor Data ....................................................................................................... 73
Types ................................................................................................................ 75
Classes and Types............................................................................................. 80
Temperature Compensation Criteria................................................................. 82
Contactor Selection Factors.................................................................................... 82
Motor Data ....................................................................................................... 82
Motor Contactor Types..................................................................................... 84
Coil Voltage Ratings ........................................................................................ 89
Auxiliary Devices ............................................................................................. 90
Disconnect/Fault Protection Selection Factors....................................................... 92
Motor Nameplate Data ..................................................................................... 92
Fault/Starting Currents ..................................................................................... 92
Types of Protective Devices ............................................................................. 93
Ratings.............................................................................................................. 95
NEC Maximum Settings................................................................................. 100
Protective Device T/C Characteristics ............................................................ 102

SIZING MOTOR CIRCUIT CONDUCTORS........................................................... 107

Introduction .......................................................................................................... 107
Motor Circuit Diagrams ....................................................................................... 107
Motor Branch Circuits .................................................................................... 107
Motor Feeder Circuits..................................................................................... 109
Motor Nameplate Data ......................................................................................... 110
Voltage ........................................................................................................... 111
Full-Load Amperes......................................................................................... 111
Service Factor (S.F.)....................................................................................... 111
Horsepower .................................................................................................... 112
Temperature Factors....................................................................................... 112
Time (Duty) .................................................................................................... 113
Locked-Rotor Codes....................................................................................... 113
Miscellaneous Data ........................................................................................ 113
Motor Branch Circuit Conductor Selection Factors ............................................. 114
NEC Tables for Motor Full-Load Amperes.................................................... 114
Short Circuit Ratings ...................................................................................... 114
Voltage Drop .................................................................................................. 115
Conduit Sizes.................................................................................................. 116
Motor Feeder Circuit Conductor Selection Factors.............................................. 117
Full-Load Amperes (All Motors).................................................................... 117
Short Circuit Ratings ...................................................................................... 117
Voltage Drop .................................................................................................. 118
Conduit Sizes.................................................................................................. 118
WORK AID 1: RESOURCES USED TO SELECT A LOW VOLTAGE
COMBINATION AC INDUCTION MOTOR STARTER ........................................ 120
Work Aid 1A: SAES-P-114 ................................................................................. 120
Work Aid 1B: IEEE Standard C37.96-1988, IEEE Guide for AC Motor
Protection ............................................................................................................. 122
Work Aid 1C: 16-SAMSS-503 ............................................................................ 127
Work Aid 1D: 1993 National Electric Code (NEC) Handbook Article
430........................................................................................................................ 128
Work Aid 1E: Manufacturer’s Literature, Westinghouse Catalog 25-000 ........... 129
Work Aid 1F: Manufacturer’s Literature, Westinghouse SA-11647,
Low Voltage Metal Enclosed Switchgear - Type DS........................................... 130
Work Aid 1G: Applicable Procedures for Selecting an O/L Relay...................... 131
Work Aid 1H: Applicable Procedures for Selecting a Contactor......................... 133
Work Aid 1I: Applicable Procedures for Selecting a Fault
Disconnect/Protective Device .............................................................................. 134

WORK AID 2: RESOURCES USED TO SIZE AC INDUCTION MOTOR

CIRCUIT CONDUCTORS ........................................................................................ 136
Work Aid 2A: SAES-P-114 ................................................................................. 136
Work Aid 2B: SAES-P-100 ................................................................................. 137
Work Aid 2C: 1993 National Electric Code Handbook Article 430 .................... 138
Work Aid 2D: Applicable Procedures for Sizing AC Induction Motor
Branch Circuit Conductors................................................................................... 139
Work Aid 2E: Motor Branch Circuit Design Flow Chart..................................... 144
Work Aid 2F: Applicable Procedures for Sizing AC Induction Motor
Feeder Conductors ............................................................................................... 145
Work Aid 2G: Motor Feeder Circuit Design Flow Chart..................................... 146
GLOSSARY............................................................................................................... 147

MOTOR STARTER CONTROL CIRCUITS
Introduction
Various types of motor starters are used to start, stop, and control motors. Depending on the
application and requirements for control of a motor, the more commonly applied starter types
include manual, full-voltage non-reversing, full-voltage reversing, wye-delta, and circuit
breaker types.
Different types of starters have different characteristics and capabilities that make them more
or less suitable for control of a given motor. The characteristics and capabilities of a starter
are determined in part by the control circuit and control logic used for the starter.
To properly apply motor starters, it is important to know and understand the types of control
circuits used for the various types of starters. Toward this goal, this Module teaches the
Participant to describe the typical components of a motor starter control circuit and to
describe the control logic used for the following five common types of low voltage starters.
• Manual starter
• Non-reversing starter
• Reversing starter
• Reduced voltage wye-delta starter
• Circuit breaker starter
Saudi Aramco DeskTop Standards 1

Control Circuit Components
Motor starter control circuits are often illustrated by means of a schematic “ladder diagram”,
similar to the one shown in Figure 1. Components used for control circuits include
pushbuttons, selector switches, indicating lights, control relays, control power transformers,
contactors, overload relays, circuit breakers, and electrical wiring. The following sections of
this Information Sheet describe the physical construction, optional variations, and mechanical
and electrical ratings of these components.
Figure 1. Typical Motor Starter Control Circuit Schematic

Pushbuttons
One component typically used in the control circuit of motor starters is the pushbutton. The
pushbutton is used to energize the control circuit. A simple pushbutton is composed of a set
of stationary contacts, a set of moving contacts, an operating plunger, a return spring, and a
housing to hold the assembly together. Pushbuttons are basically one of two types: one type
with normally open contacts, and the other type with normally closed contacts.
For the normally open pushbutton (Figure 2), the operating plunger is held up by a return
spring. This spring holds the moving contacts away from the stationary contacts, which keeps
the control circuit open and de-energized. Depressing the plunger causes the moving contacts
to engage the stationary contacts, which closes the circuit. Normally open type pushbuttons
are typically used to start a process.
Figure 2. Normally Open Pushbutton

In the normally closed pushbutton (Figure 3), the design of the contacts is opposite to that of
the normally open pushbutton. For this type, the contacts open and the process stops when
the plunger is depressed. As a result of the internal tension caused by the return spring, the
action of both the normally open and normally closed pushbuttons is momentary; when the
operator’s finger is removed from the pushbutton, it returns to its original state.
Figure 3. Normally Closed Pushbutton

The pushbuttons, which are illustrated in Figures 2 and 3, have only one set of contacts.
However, pushbuttons can accommodate multiple sets of contacts, both normally open and
normally closed. Some manufacturers construct multiple-contact pushbuttons as a single
unified assembly with the desired number of contacts included. Other manufacturers offer the
pushbutton actuators and the current carrying contacts as separate assemblies that can be
mixed and matched to suit the requirements of the application. For pushbuttons where the
contacts are offered as separate block assemblies, as many as eight blocks (circuits) can be
mounted side by side or stacked in tandem and operated from one pushbutton. The contact
assemblies are generally mounted in a transparent housing that allows visible inspection of
contact condition and status. Contact assemblies are typically available in a variety of
functional styles. Figure 4 lists two of the common functional styles offered by
manufacturers.
Figure 4. Types of Contact Assembly Blocks
To address specific application needs of selected pushbuttons, accessories are available for
use with the pushbuttons. Some of the accessories available for use with pushbuttons include
a cover to allow locking the pushbutton with a padlock, protective shrouds to prevent
inadvertent operation, and rubber boots to provide additional sealing of the pushbutton against
dust and water.

In addition to other considerations, pushbuttons are designed and manufactured to meet

various environmental requirements. They are considered to be dust tight, water tight, and/or
oil tight if, when properly mounted in a suitable enclosure, the assembly meets the applicable
design requirements given in the standards used to qualify enclosures for electrical equipment
(NEMA Standards Publication No. ICS 6 and ICS 250). In accordance with these standards,
pushbuttons are identified by a “type” number. Figure 5 lists some of the more common type
designation numbers applied to pushbuttons and the environmental conditions they protect
against.
Figure5. NEMATypeDesignation (ReferenceNEMAStd.No.250-1991)

Selector Switches
Position Versions - A position-type selector switch (Figure 6) is similar to a pushbutton in

the sense that it serves the same function, which is to energize a control circuit. However,
unlike the momentary action of the pushbutton, the position-type selector switch, once set,
maintains its contact engagement without the need of a seal-in interlock.
Figure 6. Position-Type Selector Switch

Position-type selector switches come in two functional styles: two position rotary switches
and three-position rotary switches. The two-position switch has moving contacts and
stationary contacts that allow two switch positions, one” off” position and one “selected”
position. The three-position switch has moving contacts and stationary contacts that allow
three switch positions, one “off” position and two separate “selected” positions. These
position-type selector switches are illustrated schematically in Figure 7.
Figure 7. Schematic Diagram of Selector-Type Position Switch
Like the pushbutton switch, the selector-type position switch is offered by some
manufacturers as a two-part assembly. One part is the rotary handle, and the other part is a
separate contact assembly block. Each contact block contains one set of either normally-open
or normally-closed contacts. The contact blocks listed in Figure 4 for pushbutton switches are
also available for selector-type position switches. As many as four contact block assemblies
can be mounted side-by-side or in tandem, and then operated from one rotating handle.

Selector-type position switches are also designed to meet environmental requirements. They
are identified by the same type number designation, and they must comply with the same
standards (NEMA Standards Publication No. ICS 6, and ICS 250) as pushbutton switches .
The examples of type designations listed in Figure 5 for pushbutton switches also apply to
selector-type position switches.
Circuit Breaker Control Switch - A circuit breaker control switch is a rotary power switch
designed for heavy duty control systems. Built with a spring operating action that returns the
switch to its original or neutral position, a circuit breaker switch is well suited for control
where only a momentary contact is required.
A typical circuit breaker control switch (Figure 8) consists essentially of an operating handle,
face plate, control housing, frame contact assembly, and rotor contact assembly. The frame
contact assembly and rotor contact assembly form a contact stage. Switches are identified by
the number of stages that they contain, and they may be built with from one to eight stages
mounted on the steel operating shaft.
The circuit breaker control switch shown in Figure 8 is most often used for control of medium
voltage power circuit breakers. It may, however, also be used for low voltage power circuit
breakers. Note: The control circuit logic for low voltage power circuit breakers will be
described in detail later in this Module.
Figure 8. Typical Circuit Breaker Control Switch

Indicating Lights
Indicating lights (lamps) are another component used in motor starter control circuits. Their
function is a relatively simple, but important function, which is to report the status of the
control circuit and, as a result, the status of the equipment controlled. A variety of colors are
used for the lens of the indicating lights to report or warn of various circuit conditions. Colors
typically offered by manufacturers include red, green, blue, amber, white, and clear. The
most commonly used types of indicating lights include the full-voltage, transformer, and
push-to-test types.
Full-Voltage - In a full-voltage indicating light, the lamp operates at the full voltage of the
control circuit. This voltage is applied directly to the terminals at the body of the light. For
reasons of safety, the maximum voltage rating for this type of indicating light is 120 volts
ac/dc. Other voltage ratings available for this style of light are 6, 12, 24, 28/32, and 48 volts
ac/dc.
The full-voltage indicating light is manufactured in two lamp-base styles: the candelabra style
and the bayonet style. Figure 9 shows an illustration of the two lamp-base styles.
Figure 9. Lamp-Base Styles

Transformer-Type - The transformer-type indicating light is essentially designed for use

with circuit voltages higher than 120 volts. The unique feature for this type of indicating light
is that it comes with a built-in or attached transformer that connects to the higher voltage
circuit and steps the voltage down to a safe level for the lamp. Although intended primarily
for use with circuit voltages above 120 volts, the transformer-type indicating light is also
available in lower voltage ratings. Figure 10 lists the primary voltage ratings typically
available for this style of light. Similar to the full-voltage style, the transformer-type
indicating light is available in both the candelabra and bayonet lamp-base styles.
Figure10. TypicalVoltageRatingsforTransformer-TypeIndicatingLights

Push-to-Test Type - The push-to-test type indicating light has the unique feature of allowing
its lamp to be tested for satisfactory operation without disturbing the control circuit that it is
monitoring. This test is accomplished with the use of a pushbutton that is provided as part of
the indicating light assembly. The schematic diagram shown in Figure 11 illustrates how the
test is accomplished without disturbing or altering the control circuit. As shown in Figure 11,
operating the pushbutton for the indicating light completes the circuit from one side of the
supply voltage, through the light, to the other supply line. In this manner, relay and pilot
contacts are left undisturbed, while the lamp is energized and de-energized for verification of
operation.
Figure 11. Push-To-Test Indicating Light
The push-to test light is available as both a transformer-type indicating light and a full-voltage
type indicating light. For the transformer-type, it is offered in voltage ratings of 120/110,
240/220, and 480 volts. In the full-voltage type, it is offered as a bayonet base lamp or LED
(Light Emitting Diode) at voltage ratings of 12, 24, and 120 volts ac/dc.

Control Relays
A control relay is a component that is used in a motor starter’s control circuit to interface
between a pilot device and the circuit that the pilot device controls. In effect, the control relay
allows the pilot device to control a current that is too large for the contacts of the pilot device.
Pilot devices that are used in motor controls typically monitor parameters such as time,
pressure, liquid level, and heat. When the pilot device activates, it allows the control relay to
pick up, which in turn allows a higher current control circuit to be energized. For some cases,
more than one pilot device may have to be activated before a control circuit is permitted
(through the control relay) to be activated.
Several types of control relays are available for use in control circuits. Some common types
include electromechanical, solid-state, and timer relays. Most of these relays are available in
either 4 or 6-pole configuration. Many types can be easily converted to 8 or 10 pole
configurations by adding an additional 4-pole unit. Contacts are convertible between
normally open (NO) and normally closed (NC).
Electromechanical - One type of control relay is the electromechanical type (Figure 12a).
This control relay uses an electromagnet to move the output contacts from open to closed and
closed to open. Relays of this type are referred to as alternating current relays, if designed for
actuation from an ac source, or direct-current relays, if designed for dc operation.
The contact construction for electromechanical relays may be convertible, fixed, or universal.
Convertible construction allows contacts to be changed in the field from normally open to
normally closed and vice versa. Fixed construction means contacts are either normally open
or normally closed, and the contacts cannot be changed in the field. Universal construction
provides both a normally open and a normally closed set of contacts on each pole of the relay,
but only one or the other set of contacts may be used.
Solid-State - The solid-state control relay (Figure 12b) performs the same function as the
electromechanical control relay; that is, it controls the flow of current in a control circuit in
response to a lower level signal from a pilot device. However, the method used by the solid-
state device to close and open the current flow is very different. The solid-state relay uses
semiconducting devices (i.e. SCR’s and transistors) instead of open-air contacts for the
switching operation.

Figure 12. Typical Control Relays

Control Power Transformers (CPT)
The voltage required to operate the control circuit is normally taken from the main power
circuit of the motor starter, as shown in Figure 1. A control power transformer (CPT) is used
to connect the power circuit to the control circuit. The CPT is a standard single-phase
transformer design consisting of two windings connected by a common core. Power is
transformed from the primary to the secondary winding in accordance with the principles of
magnetic induction. The CPT is selected and sized according to the voltage and voltampere
ratings of its windings.
Voltage Ratings - Control circuits are designed to operate at relatively low voltage levels
(110 to 120 volts ac) for the safety of operating personnel. Motor starter power circuits,
however, operate typically at one of several higher voltage levels. For this reason, CPTs are
available in a variety of voltage ratings and voltage ratio combinations. When sizing a CPT
to match the power circuit ratings, the winding voltage ratings must be selected to match the
voltages of the control and power circuits. More commonly, the CPT is sized and provided
by the manufacturer as an integral part of the controller. Figure 13 lists the voltage ratings for
typical CPTs available from one manufacturer.
Figure 13. Typical Voltage Ratings for Control Power Transformers

Voltampere Ratings - In addition to the voltage rating of the windings, the CPT is also
voltampere (VA) rated. With the voltage rating of the windings identified, the VA rating
determines the maximum current that the winding can carry without overheating. As an
example, for a transformer rated at 500 VA, with a primary winding of 480 volts and a
secondary winding of 120 volts, the maximum safe primary current is 1.04 amperes (500 VA/
480 V). The maximum safe secondary current is 4.2 amperes (500 VA/ 120 V). Typical VA
ratings available for CPTs range from 50 VA to 2000 VA. Similar to the voltage rating of the
windings, the VA rating for the CPT is commonly determined by the manufacturer when the
transformer is supplied as part of the controller. Figure 14 lists the typical VA ratings of
CPTs with NEMA sized contactors 00 through 6.
Figure14. TypicalVoltampereRatingsforControlPowerTransformers

Wiring
The types of control wiring used for combination controllers are determined and provided by
the manufacturer as an integral part of the combination controllers. The wiring types used are
selected in accordance with customer, NEMA, and NEC standards. Figure 15 lists the types
of controllers that Saudi Aramco uses. Referring to this figure helps to identify the
combination controllers used by Saudi Aramco that have their wiring provided as an integral
part of the controller.
Figure 15. Types of Controllers
With regard to the type of control wiring used for low-voltage controllers, 16-SAMSS-503
specifies that all wiring used for motor controllers rated 600 volts and below must be stranded
electrical grade copper wiring with 600-volt insulation.
With regard to the size of control wire used in combination starters, the manufacturer selects
the size (as was done in selecting wire type) in accordance with customer specifications, and
NEMA and NEC standards. Saudi Aramco requirements for control wiring for low-voltage
controllers are specified in 16-SAMSS-503. The requirement per this specification is that all
conductors must be a minimum size of 2.5 square mm (No. 14 AWG).

Contactor
In a motor starter circuit, the contactor is normally considered to be part of the power circuit
because it makes and breaks the circuit carrying the motor current. However, the contactor is
unique in the sense that a portion of its elements are connected in the power circuit (the main
motor current contacts), while the remainder of the elements are connected in the control
circuit (coil and auxiliary contacts).
Figure 1 (Typical Motor Starter Schematic) shows the connection of the contactor coil
(labeled “M”) and the auxiliary contacts (labeled “Ma” and “Mb”) for a full-voltage non-
reversing starter. The main function of the contactor coil is to magnetically open and close
the main contacts, also labeled “M”, which control the operation of the motor. The coil is
physically mounted on a core that is constructed of thin, individual metal laminations that are
riveted together. The core and coil form an electromagnet. Energizing the coil causes an
armature (mechanically linked to the main contacts) to operate, which opens and closes the
main contacts. Contactors are available with either ac or dc voltage coils.
The auxiliary contacts associated with the main contactor are identified with the capital letter
M and the subscripts a and b (Ma, Mb). The auxiliary contacts may be contained within the
contactor assembly, or they may be provided as an attachment accessory. The auxiliary
contacts are commonly provided in sets of two, with one normally open contact and one
normally closed contact. The auxiliary contacts are designed to interlock the main contactor
with the control circuit, and they are designed to carry no more than 10 amperes continuously.

AC Coils - Contactors with alternating-current (ac) coils are available in a wide range of coil
voltage ratings (24 volts ac to 600 volts ac). In accordance with NEMA Standard ICS 2-110,
ac-operated contactors must withstand 110 percent of their rated voltage continuously without
injury to the operating coil, and they must close successfully at 85 percent of their rated
voltage. Figure 16 lists the typical operating characteristics of ac coils for contactor sizes
NEMA 00 through NEMA 6.
Figure 16. Typical Operating Characteristics for AC Coils

DC Coils - Contactors are also available with coils that operate on direct current. Typical
voltage ratings for these coils range from 24 to 250 volts dc. In accordance with NEMA
Standard ICS 2-110, dc operated contactors must withstand 110 percent of their rated voltage
continuously without damage to the operating coil, and they must close successfully at 80
percent of their rated voltage. Figure 17 lists the typical operating characteristics of dc coils
for contactor sizes NEMA 00 through NEMA 6.
Figure 17. Typical Operating Characteristics for DC Coils

Circuit Breaker or MCP
Molded-case circuit breakers (MCCBs) are a class of breaker that are rated at 600 volts and
below, and they consist of a switching device and an automatic protective device assembled
in an integral housing of insulated material. MCCBs are capable of clearing a fault more
rapidly than a low voltage power circuit breaker (LVPCB) can clear a fault. Solid-state trip
units incorporated into some styles of MCCBs provide for their coordination with LVPCBs.
MCCBs are generally sealed to prevent tampering, which in turn precludes any inspection of
the contacts. MCCBs are generally not constructed to be maintained in the field, and
manufacturers recommend total replacement if a defect appears.
MCCBs are available in several different types. The thermal-magnetic type, which is the
most widely used, employs thermal tripping for overloads and magnetic tripping for short
circuits. The magnetic type employs only instantaneous magnetic tripping for cases where
only short circuit interruption is required. The integrally-fused type combines regular
thermal-magnetic protection together with current limiting fuses to respond to applications
where higher short circuit currents are available. In addition, the integrally-fused current
limiting type offers high interrupting capacity protection, while at the same time limiting the
let-through current to a significantly lower value than is usual for conventional MCCBs.
The motor circuit protector (MCP) is a specific class of MCCB, which has a special adjustable
instantaneous trip circuit designed primarily for motor short circuit protection. Major features
of the MCP are that it can respond to the occurrence of low level faults in motor windings and
typically clear them as fast (less than one cycle) as a fuse. SAES-P-114 permits use of MCPs
for low voltage motor protection for motors that are rated 1 to 100 horsepower.
LVPCBs, like MCCBs, are rated 600 volts and below. They differ, however, because they are
typically open-construction assemblies on metal frames, with all parts designed for accessible
maintenance, repair, and ease of replacement. LVPCBs are intended for service in switchgear
compartments or in other enclosures of dead- front construction. Tripping units are field-
adjustable, and include electromagnetic, direct-acting, and solid-state types. LVPCBs can be
used with integral current limiting fuses to meet interrupting requirements up to 200 kA RMS
symmetrical. SAES-P-114 specifies the use of LVPCBs for low voltage motor fault
protection for low voltage motors that are rated greater than 100 horsepower.

Overload (O/L) Relay
The O/L relay is another component in the motor starter that is connected in both the power
circuit of the motor and the control circuit of the motor starter. As illustrated in Figure 1, the
thermal sensing elements of the O/L relay for low voltage starters are connected directly in
series with the conductors that carry the current to the motor (for large horsepower-rated
starters, the O/L relays are connected through current transformers). O/L relays are available
from manufacturers in a three-pole configuration, with three thermal elements (one in each
pole), or as a single-pole relay with one thermal element. Both configurations are provided
with one normally closed contact that opens when an overload condition is detected. For
three-phase motors, one three-pole O/L relay or three individual single-pole O/L relays can be
used to provide the overload protection. The advantage of using three single-pole O/L relays
is that this arrangement provides better protection against a “single-phase” condition for the
three-phase motor. On the other hand, three-pole O/L relays provide only limited protection
against a “single-phase” condition.
The normally closed relay contact (identified as “OL” in Figure 1) is connected in the control
circuit of the motor starter. When mechanically operated by the thermal sensors, in response
to a timed overcurrent, the contact interrupts the current flow to the contactor coil. This
current interrupting action opens the contactor and shuts down the motor. The current rating
of an O/L relay is expressed in amperes at an ambient temperature of 40oC. Ratings for O/L
relays are given as a range of motor full-load amperes. Figure 18 lists a few of the current
ratings for one type of O/L relay for low voltage starters.
Figure 18. Example of Overload Relay Ratings

Control Logic Description: Manual Starter
Manual motor starters are used where only on-off operation is required for small, single or
three-phase motors, and full voltage across-the-line starting is acceptable. General application
includes control of small ac and dc motors where remote control is not required, where the
operator is in attendance at the driven load, and where conditions eliminate any hazard due to
sudden restarting of motors upon restoration of power. The sizes of motors that are controlled
with manual starters are typically limited to ratings of 10 hp or less.
Toggling
The simplest type of manual starter is a 1, 2, or 3-pole toggle-operated switch that is used for
infrequent starting/stopping of small motors. The toggle-operated switch consists of a basic
snap-action mechanism that connects the motor to the line in the “on” position and that
disconnects the motor when in the “off” position. The toggle switch has a third position
called the “trip” position, which is the position of the handle after the thermal device trips the
starter. When in the “trip” position, the handle must be manually moved to the “off” position
before it can again be switched to the “on” position. When the switch is mounted inside an
enclosure, the toggle handle that operates the contact assembly protrudes through the
enclosure cover. To provide running O/L protection, the switch contains a thermal device to
open the circuit on overloads (Figure 19). The thermal unit is typically a plug-in element that
is keyed for proper positioning in the switch. Elements are typically rated at 115% to 125%
of full load amperes, with the rating being marked directly on the element.
Figure 19. Fractional Horsepower Toggle Switch Starter

Pushbutton
Manual starters also can be provided with pushbuttons for operation of the starter. For
pushbutton operation, the pushbuttons are mechanically coupled to the contact assembly, as
illustrated in Figure 20. The pushbutton type starter has a “start” pushbutton to connect the
motor to the line, an “off” pushbutton to disconnect the motor, and a pop-out trip indicator
that serves as a “reset” pushbutton to reset the starter following a trip operation by the thermal
device.
Figure 20. Integral Horsepower Pushbutton Starter (Manual)

Mechanical Tripping
Tripping or opening of the manual type starter is accomplished by one of two methods. The
first tripping method is to operate the toggle handle (or pushbutton) manually. The toggle
handle (or pushbutton) is mechanically linked to the mechanism that operates the contacts.
To ensure that the contacts move with sufficient velocity to reliably make and break their
rated current, the mechanism is designed to provide a very quick “snap-action” operation.
Manually operating the toggle handle (or pushbutton) is generally intended for opening the
motor circuit under normal running current conditions.
The second tripping method is accomplished automatically by the thermal device when an
overcurrent exists for a period of time that exceeds the time-current characteristics of the
device. The thermal device is mechanically linked to the contact operating mechanism in a
manner similar to the toggle handle. When an overcurrent is determined to exist for a longer
than allowable period, the thermal device mechanically operates the contact opening
mechanism in the same manner as the toggle handle.
Reset
The thermal device provides running overload protection for the manually toggle-operated (or
pushbutton-operated) starter by opening the circuit on overloads. When the thermal device
trips the starter, the starter toggle handle is left in the “trip” position. The toggle handle (or
pushbutton) must be then manually reset from the “trip” position to the “off” position, after
cooling, before it can be physically switched to the “on” or closed position. This resetting
procedure is a safety precaution that is built into the starter switch, and it is known as a “trip
free” switch design. In addition to requiring the toggle handle to be reset to “off” after
overload tripping, the trip free switch design prevents holding the switch closed against a
sustained motor overload.
Although manual starters are equipped with overload protection, they do not have low voltage
(undervoltage) protection. As a result, the motor is not protected against overheating that can
be caused by low voltage. Another problem that exists is that a power failure or other loss of
voltage to the motor circuit will cause the motor to stop, but it will not be disconnected from
the supply circuit. For this condition, the starter contacts remain closed and the motor will
restart immediately on restoration of power.
Note: The above information on manual starters is provided for the general knowledge of the
Participant. Saudi Aramco standards do not permit use of manual motor starters.

Control Logic Description: Non-Reversing Starter
The full voltage non-reversing motor starter is relatively simple in construction, is easy to
maintain, and is the least expensive of all ac motor starters. This type of starter is used for
control of three-phase motors where full-voltage starting is acceptable, and where the motor
runs only in one direction. The control circuit used for control of the full-voltage non-
reversing starter is normally one of two types, either the three-point control circuit (Figure 21)
or the two-point control circuit (Figure 22).
Three-Point
Figure 21 shows a three-point (or three-wire) control scheme with the control wiring tapped
off the line-side terminals of the starter. Because the control circuit receives its current supply
from the same branch circuit that supplies the power to the motor, the control circuit is also
de-energized when the disconnecting means (MCP) ahead of the starter is opened. The three-
point circuit gets its name from the fact that this circuit requires three points for connection of
the pushbuttons to the starter.
Figure 21. Full Voltage Non-Reversing Motor Starter

(Three-Point Control Circuit)

To trace the operation of the three-point control circuit, it is important to first note two items.
First, the pushbuttons are the momentary type, which means that the pushbuttons open or
close for only as long as they are pushed. Once released, the pushbuttons return to their
original state (either normally-open or normally-closed). The second item to note is that all
components are shown in the diagram in their de-energized (or shelf) state. With these two
items of information noted, the operation of the circuit can be described. When the start
button is pushed, the circuit to the starter’s contactor coil is completed, and the main contacts
of the starter close allowing current to flow to the motor. At the same instant, the red
indicating light is turned on, and the auxiliary contacts Ma and Mb operate. Contact Ma,
which is normally open, changes to the closed position, completing the circuit around the start
button so that the circuit to the main coil (M) is maintained when the button is released.
Contact Ma is referred to as the seal-in contact because the control circuit is now sealed-in
until the stop button is operated. Auxiliary contact Mb, which is normally closed, opens and
turns off the green indicating light. Under these conditions, the motor is connected directly
across the line, and the motor starts at full voltage. When it is desired to stop the motor,
momentary depression of the stop button opens the control circuit, de-energizing coil M,
which removes the power to the motor. As before, the auxiliary contacts Ma and Mb operate
in unison with the main contactor. By the time the stop button is released, the Ma contact of
the starter opens and blocks the circuit to the starter coil, and the Mb contact closes and turns
on the green indicating light. The motor can only be restarted by once again pushing the start
button.
Voltage Self-Protection - also known as undervoltage protection, is an important protection

characteristic of the three-point control circuit. The action of this characteristic can be
described by again noting that when the start button for the three-point control circuit in
Figure 21 is pushed, the contactor coil is energized, and the Ma auxiliary contact seals the coil
circuit closed. Following this action, if the line voltage dips too low or fails altogether, the
coil will not be able to hold the contacts closed. Generally, the contactor coil is unable to
hold the contacts closed if the voltage falls below 50% to 60% of normal voltage. Therefore,
a prolonged (more than a few cycles) drop of voltage at the starter terminals can cause the
starter to open. Should the starter open due to voltage failure, the Ma contact also opens,
which releases the seal-in connection across the coil. As a result, the starter cannot reclose on
restoration of voltage. In order to reclose the starter, the start button must be pushed again.
This voltage protection characteristic of the three-point control circuit eliminates the hazard of
uncontrolled restarting of a motor.
Seal-In Contact Ma is an auxiliary contact physically located on the main starter contactor
and mechanically linked to operate in unison with the main contacts. Ma is a normally open
contact, which means that it is in the open position when the contactor coil is de-energized.
The Ma contact is often referred to as the seal-in contact because, as described above, it is
used to seal in the circuit that energizes the contactor coil after the start button is pushed. The
main contactor has a normally closed auxiliary contact identified as Mb. The Mb contact is
commonly used for operation of indicating lights or other control functions. When needed,
an Mb auxiliary contact can be added to a contactor as an accessory attachment.

Two-Point (Hand-Off-Auto)
The two-point control circuit, as shown in Figure 22, uses a position-type selector switch in
place of pushbuttons. The position-type switch is similar to the pushbutton in the sense that it
serves the same function, which is to energize the control circuit. However, unlike the
momentary action of the pushbutton, the position-type selector switch, once set, maintains its
contact engagement without the need of a seal-in interlock. Position-type switches are
normally provided with either two or three selectable positions. The two-point control circuit
gets its name from the fact that this arrangement requires two points of connection between
the source of control voltage (terminal 1 of the control circuit fuse) and the contactor coil.
The two-point control circuit in Figure 22 shows the use of a three-position switch, which
offers a third or “auto” position for use, when it is desired to switch the control of the motor to
an external source.
The operation of the two-point control circuit shown in Figure 22 can be described beginning
with the manual movement of the selector switch to the “hand” position. Rotating the selector
switch to the “hand” position energizes the starter contactor coil, which in turn closes the
main contacts, and allows current to flow to the motor terminals. Because the selector switch
maintains engagement, it does not require a seal-in circuit, and it remains in the closed state
until manually changed. To stop the motor, the selector switch is manually rotated to the “off”
position, which de-energizes the contactor coil and opens the main contacts to stop the motor.
A unique (and sometimes dangerous) characteristic of the two-point control circuit is that
following a power failure, the motor will automatically restart upon return of power. As a
result, the two-point control scheme is typically only used in cases where the motor is
required to be controlled by a remote (sometimes called permissive) device, such as a
thermostat, pressure switch, float switch, or limit switch.

Figure 22. Full Voltage Non-Reversing Motor Starter

(Two-Point Control Circuit)

Overload Relay Contacts
Figures 21 and 22 show the normally closed contact of the overload relay (marked “OL”) in
series with the starter contactor coil “M”. When an overload condition occurs, the overload
contact opens, which de-energizes the contactor coil and stops the motor.
Automatic Reset of the overload relay contacts after operation and cooling is a feature
provided on some types of overload relays. The automatic reset is a convenient function for
use with motors that are located in remote areas. Relays having the automatic reset feature
can also be adjusted and used in the manual reset mode. The manufacturer normally
furnishes this type of relay set to the manual reset mode, and the customer has the option of
adjusting it to the automatic reset mode.
Manual Reset of overload relay contacts is the more commonly used type of reset mode.
This manual reset mode provides added safety by requiring an intentional reset of the relay
before the motor can be restarted, which usually prompts an inspection by the operator to
determine the cause of trip before restarting. To accomplish a manual reset, the operator,
following an overload trip and cool down period, must physically push or operate the reset
button (plunger). For two-point control circuits, the manual reset function is preferred to
eliminate the hazard of uncontrolled restarting of motors.
Run and Stop Indicator (Pilot) Lights
Run and stop indicating (pilot) lights are optional pilot devices for motor starters. The
standard practice is to use a green light to indicate that the motor is switched-off (de-
energized and not running) and a red light to indicate that the motor is switched-on (energized
and running). As illustrated in Figures 21 and 22, the red light is wired in parallel with the
terminals of the starter contactor coil, and it is turned on and off in unison with the energizing
and de-energizing of the coil. Operation of the green light is controlled by the normally
closed auxiliary contact Mb, and it is switched on and off directly opposite to that of the red
light.
Control Logic Description: Reversing Starter
The full-voltage reversing motor starter is used where it is necessary to start and run a motor
in either direction (forward or reverse). The direction of rotation of three-phase induction
motors is easily reversed by simply interchanging any two of the three line connections to the
motor. Reversal of the motor connections is accomplished through control of the contactors
mounted in the motor starter.

Full-Speed Reversing (Small Size Motors)
One type of control logic used in full-voltage reversing starters is the full-speed reversing
logic. The circuit arrangement for this type logic allows the direction of a motor to be
reversed without pushing the stop button. Use of this type of logic is acceptable only for
small motors with relatively low mass and low inertia.
The circuit arrangement for full-speed reversing is shown in Figure 23. The arrangement of
this circuit is basically the same as for all full-voltage reversing starters, except that the
forward pushbutton and the reverse pushbutton have an additional normally-closed contact
block. The starter has two contactors, one connected to apply the three phases to the motor so
that the motor starts and runs in the forward direction. The other contactor is connected so
that when it closes, two of the lines to the motor are interchanged, which reverses the
direction of rotation of the motor.
For the circuit shown in Figure 23, starting the motor and operating it in the forward direction
is initiated by closing the forward pushbutton. This action energizes the forward contactor
(F), which in turn closes the main contacts to the motor terminals, which starts the motor in
the forward direction. The same action that closes the normally open contact of the
pushbutton also opens its normally closed contact. This temporary open circuit prevents an
unwanted start in the reverse direction. As the forward contactor operates, it causes its
auxiliary contacts to also operate. The normally open auxiliary forward contact (Fa) closes to
seal in the forward coil circuit, and the normally closed auxiliary forward contact (Fb) opens
to block the reverse contactor coil circuit.
To reverse the direction of the motor (without first pushing the stop pushbutton), requires
simply pushing the reverse pushbutton. The opening of the normally closed contact of the
reverse pushbutton causes the coil circuit for the forward contactor (Fb) to momentarily open.
The circuit for the reverse contactor coil (R) circuit momentarily closes. When the forward
contactor opens, it operates its auxiliary contacts (Fa , Fb). Fa opens to keep the forward (F)
coil circuit open, while Fb closes to allow the reverse coil (R) circuit to energize.
When the reverse contactor picks up, it closes it main contacts to the motor terminals, which
in this case causes lines L1 and L3 to be interchanged, reversing the direction of the motor.
Auxiliary contacts Ra and Rb operate in unison with the reverse contactor. The normally open
Ra contact closes to seal in the reverse coil circuit, while the normally closed Rb contact opens
to block the energizing of the forward coil circuit.

Figure 23. Full-Voltage, Full-Speed Reversing Motor Starter
Stop Before Reversing (Medium Size Motors)
The stop before reversing logic is generally used for medium size motors. Stopping the motor
first, before reversing its direction, eliminates the overcurrent surge and potentially damaging
mechanical stress that can result with the attempt to rapidly reverse a large rotating inertia
(load). Figure 24 shows the circuit arrangement for a stop before reversing logic. The basic
difference between this circuit and the one described in Figure 23 is the arrangement of the
pushbutton contacts.

Figure 24. Full-Voltage (Stop Before) Reversing Motor Starter
Operation of the circuit in Figure 24 begins by closing the forward pushbutton to energize the
forward contactor coil (F), which closes the main forward contacts to the motor terminals, and
starts the motor in the forward direction. In sequence with this action, auxiliary contact Fa
closes to seal in the forward coil (F) circuit, and auxiliary contact Fb opens to block the
reverse coil (R) circuit. To reverse the motor when it is running in the forward direction, it is
necessary to first push the stop pushbutton. Pushing the stop pushbutton de-energizes the
forward contactor, which in turn opens the main forward contacts and allows Fa to open and
Fb to close. At this point, the reverse pushbutton can be pushed to energize the reverse
contactor coil circuit. In sequence, the main contacts of the reverse contactor close (reversing
motor lines L1 and L3), Ra closes to seal in the reverse coil circuit, and Rb opens to block the
forward coil circuit.
The circuit logic for the stop before reversing starter requires only that the stop button be
pushed before an attempt is made to reverse the direction of the motor. Based on the motor’s
size and inertia, whether the motor is allowed to come to a complete stop before actually
reversing is a decision that the operator makes.

Time-Out Before Reversing (Large Size Motors)
Large motors must be brought to a complete stop before attempting to reverse their running
direction. This stopping precaution is necessary because of the large mass and resulting high
inertia of the motor. High inertia could cause intolerably high motor current and possible
mechanical damage if direction reversal were attempted while the motor was still turning.
A circuit logic, referred to as time-out before reversing, is used to stop the motor before
reverse. The circuit arrangement for this logic is identical to the one shown in Figure 24, with
one exception. The exception is that either a timing relay or speed sensor is added to the
circuit.
When a timing relay is used, the relay is connected to begin its timing cycle whenever the
stop pushbutton is pushed. The timing relay contacts prevent the energizing of the contactor
coil for the opposite direction until after the relay has completed its predetermined time cycle.
The cycle is preset to allow the motor sufficient time to come to rest.
When speed sensors are used, the control contacts for the sensors are connected in series with
the contactor coil circuits. The sensors continuously monitor the speed of the motor. On
pushing the stop pushbutton, the sensor control contacts prevent energizing the contactor coil
for the opposite direction until after the motor comes to a stop.
Mechanical and Electrical Interlocks
All reversing starters have two magnetic contactors mounted in one enclosure. The contactors
provide for connection of the power leads to the motor terminals. One contactor (forward
contactor) is connected to the apply the three phases to the motor so that the motor starts and
runs in the forward direction. The other contactor (reverse contactor) is connected so that
when it closes two of the lines to the motor are interchanged, which reverses the direction of
rotation of the motor.
With regard to the operation of the two contactors, it is necessary that they be interlocked to
prevent both contactors from closing at the same time. If both contactors were closed at the
same time, the result would be a short circuit across two of the phases. Both mechanical and
electrical interlocks are used to prevent this short circuit condition. Mechanical interlocks
typically use an insulated linkage fastened between the moving assemblies of the two
contactors to prevent their simultaneous closing. Electrical interlocking circuits vary in
purpose and complexity, but the basic technique consists of using normally open and
normally closed contacts (Fb, Rb) in both the forward and reverse coil circuits to maintain
each coil circuit open while the other is closed.

Control Logic Description: Reduced-Voltage Wye-Delta Starter
Another type of motor starter is the reduced-voltage wye-delta starter (Figure 25). This type
of starter uses the method of connecting the motor windings into a wye configuration to start,
and then switches the windings into a delta configuration to run. The following paragraphs
describe the logic for this type of starter.
Figure 25. Reduced-Voltage Wye- Delta Motor Starter

A six-lead motor that is normally connected delta for rated voltage can be started with
reduced inrush current and torque by connecting the windings in a wye configuration during
acceleration. After the motor is accelerated to full speed, magnetic contactors quickly
reconnect the windings to a delta configuration for rated operation. With the windings
connected in a wye connection, it is equivalent to starting on a 57% (1/ 3 ) autotransformer
tap and providing the motor with 33% (.572) of full-voltage starting torque.
Operation of the control circuit shown in Figure 25 begins by closing the start pushbutton.
This closing action energizes and closes start contactor S, which closes contact Sa and picks
up contactor 1M. At the same time, contact Sb opens to block 2M from picking up. The main
contacts of the S contactor connect motor terminals T4, T5, and T6 to make a wye
connection. The 1M contacts connect the supply lines L1, L2, and L3 to motor terminals T1,
T2, and T3. With the windings connected in this wye arrangement, the motor accelerates to
full speed. With the closing of contact Sa, the time delay relay TR is energized and begins
timing the transition (starting) period. After the timing relay TR times out, its contacts open,
dropping out contactor S. Although auxiliary contact Sa opens, contactor 1M remains closed
due to the seal-in 1Ma auxiliary contacts. Auxiliary contact Sb closes to pickup 2M. With 1M
remaining closed, the 2M contacts now connect the motor windings into a delta circuit by
connecting supply lines L1, L2, and L3 to the motor terminals T4, T5, and T6. The motor
now operates at full (delta-connected) voltage.
Because it does not require the use of resistors or autotransformers, the wye-delta type starter
has the advantage of being relatively inexpensive. However, offsetting this advantage are a
few disadvantages. First, there is no method of adjusting the starting torque. If one-third
normal torque cannot turn the motor or if the acceleration is too slow, the wye-delta starter is
not a practical choice. Second, use of this type of starter requires a special motor with all six
leads brought out to the terminal box. Finally, the starter, as shown in Figure 25, is an open
transition type, which means that the motor is briefly disconnected for the transition from a
wye to a delta connection.
Mechanical and Electrical Interlocks
Because the closing of both contactors at the same time would result in a three-phase short
circuit directly across the power supply lines, interlock protection for the S and 2M contactors
is absolutely necessary. To prevent S and 2M from closing at the same time, they are
interlocked both electrically and mechanically. Electrical interlocking is accomplished by
means of the normally closed Sb and 2Mb auxiliary contacts, which maintain each coil circuit
open while the other coil circuit is closed. Mechanical interlocking of the S and 2M
contactors is accomplished by means of the standard manner of interconnecting their moving
assemblies with an insulated mechanical link.

Transition Timer
The reduced-voltage wye-delta starter starts the motor with the windings connected in a wye
configuration and then, using its contactors, transitions to a delta winding configuration. The
time required for the motor to accelerate to full speed while connected in wye is referred to as
the transition time, and it is preset by the setting of the timing relay TR. When the TR relay
times out, its contacts open, dropping out the starting contactor (S), which in turn switches in
the 2M contactor that completes the transition by reconnecting the winding in delta. Allowing
the motor to run for a longer time period while connected in the wye configuration does not
harm the motor. However, in the wye configuration, the motor has only one-third of its full-
load torque capability, and it is necessary to transition to the delta connection to provide the
motor with full torque capability.
Control Logic Description: Circuit Breaker Starter
The circuit breaker is tripped on overload and short circuit conditions by the combined action
of three components: the sensors that determine the current level, the solid-state trip unit that
provides a tripping signal when predetermined current levels are exceeded, and the actuator
that actually trips the circuit breaker. Figure 26 is a schematic illustration of an Amptector
(Cutler-Hammer/Westinghouse) tripping system. Note: Other tripping systems have different
solid-state trip units, but the schematic is basically the same.
Figure 26. Schematic Illustration of a Tripping System

Modern day low voltage power circuit breaker trip units are very flexible and they cover a
wide range of tripping characteristics. Not only are the trip units adjustable, but the sensors
are also available over a wide range of current ratings.
The automatic overload and short circuit tripping characteristics for a specific breaker rating,
as determined by the sensor rating, are determined by the settings of the solid-state trip unit.
This tripping unit also supplies a pulse of tripping current to the actuator. Therefore, all
tripping functions are performed by secondary control circuitry, with no mechanical or direct
magnetic action between the primary current and the mechanical tripping parts of the breaker.
The electrical operation (logic) of the spring charging motor circuit shown in Figures 27a and
27b is as follows:
• With the breaker open and springs discharged, the motor (MOT) is energized
through the limit switch (LS) and the “b” contact. The green indicating lamp
(G) is controlled by a separate “b” contact, and, when lit, indicates that the
breaker is open.
• The motor runs and charges the closing springs.
• When the springs are fully charged, limit switch (LS) opens in the motor circuit
and closes in the spring release coil (SR) circuit.
• When the close contact (CS-C) makes, the spring release coil (SR) is energized
through the normally closed “Y” contact, the limit switch (LS), and breaker “b”
contacts, which releases the latch holding the stop roller on the close cam.
• Springs are released to close the breaker. When the breaker closes, the “b”
contact opens to cut off the spring release coil and the motor, and the limit
switch (LS) contacts reset.
• If the close contact (CS-C) is maintained, the “Y” anti-pump relay will be
picked up by the current through the SR coil, and will open its “Y” contact in
the SR circuit, which allows only one close operation until the close contact
(CS-C) has been reset. The “Y” coil has a very low drop-out voltage.
• On some circuit breakers, a special closing circuit may be provided, which

permits the closing springs to be automatically recharged immediately after the
breaker is closed, instead of only after the breaker is opened. This automatic
recharging is accomplished by separating the motor and limit switch from the
“b” contact so the motor operation is independent of the position of the breaker
contacts. This arrangement makes the breaker suitable for use with
instantaneous reclosing relays or in special operating sequences.

• The standard control utilizes ac or dc control power. For 240 or 120 volt ac
equipment, the control power may be taken directly from the source through
fuses. For 480 and 600-volt operation, a suitable control power transformer is
used. The transformer is optional for 240 volt systems. DC control voltages
are 48, 125, or 250 volts.
• When the breaker is closed, the “a” contact in the shunt trip (SH-TR) coil
circuit also closes to complete this trip circuit. The red indicating lamp (R)
supervises the shunt trip circuit to show that it is in working order, and it
indicates that the breaker is closed.
• When control power is turned on, any power-operated breaker in the test or
connected position with its springs discharged will have its motor energized
until the closing springs are charged.
Figure 27a. Amptector Trip Unit Schematic Diagram

Figure 27b. Amptector Trip Unit Connection Diagram

MOTOR PROTECTION REQUIREMENTS
Introduction
There are numerous variables involved in selecting motor protection: motor size (kW or hp),
voltage, type of controller, motor importance, etc. The protection for each specific motor
installation must be chosen to meet the requirements of the type of motor and its use.
Although this Information Sheet will describe the generic protection requirements for low
voltage motors, Saudi Aramco and other industry standards must be used to choose the
specific Saudi Aramco requirements, depending on the size, voltage, and application of the
motor.
Motor T/C Characteristic Curves
Thermal Capability Curve
Heating characteristics of motors are very difficult to obtain and they vary considerably with
motor size and design. These heating characteristics are modeled as curves, and they are an
approximate average of an imprecise thermal zone, where varying degrees of damage of
shortened insulation life may occur. Figure 28 shows a typical motor capability curve, which
is the motor designer’s estimate of the amount of load current that may flow in the motor
without exceeding permissible temperatures. The locked-rotor time (tLR), shown in Figure 28,
depicts the starting time of the motor (current versus time), which is based on starting the
motor cold (the motor windings, rotor, etc., are at ambient temperature). To prevent motor
damage, if the motor’s duty cycle permits hot starts, the motor windings, rotor, etc., are at an
elevated temperature, and the manufacturer must be consulted to determine a permissible
starting time (ts).
Motor Starting Curve
The starting current is represented by the curve (solid line) as previously described in Figure
28, and the currents (labeled LRAa and LRAs) that are shown in Figure 29.
Locked-Rotor Current - Symmetrical - After the transient current decays, the starting
current hovers near the symmetrical starting current (LRAs). The magnitude of this starting
current is typically 4 to 6 times the motor’s full-load amperes (FLA). The exact magnitude is
based on the subtransient reactance (X”d) of the motor, which ranges from 16.7 to 25 percent.

Locked Rotor Current - Asymmetrical (dc Transient) - Because of the transient direct
current, the asymmetrical starting current (LRAa) exceeds the symmetrical locked rotor
current (LRAs) during the first few cycles. This transient current appears, as it does under
fault conditions, because the series reactance (inductance) prevents an instantaneous change
in the magnitude of the alternating current. The magnitude of the asymmetrical starting
current is approximately 1.5 x LRAs for low voltage motors and 1.6 x LRAs for medium
voltage motors.
Starting Time - The starting time (ts) of the motor is the approximate time that it takes the
motor to approach rated running speed. For purposes of this course, it is assumed that the
starting time (ts) is less than the locked-rotor (stall) time (tLR).
Full-Load Current - After the motor reaches rated speed, it acquires its normal rated current
value (full-load amperes), assuming rated load, voltage, and frequency.
Figure 28. Motor Curves

Figure 29. Motor Starting Current
Thermal Protection
Thermal Overload (O/L) Protection
Thermal O/L protection is always applied to motors to protect them from overheating. NEC
Article 430-38 requires an O/L device in each phase except “where protected by other
means”. This O/L protection requirement (one-per-phase) is necessary because single
phasing of the primary in a delta-wye configuration results in a 2:1:1 three-phase motor
current relationship. O/L protection is provided by replica-type relays for small kW-rated
motors. Replica-type relays operate directly from motor circuit current. They receive their
name “replica” because they tend to “replicate” the heating characteristics of the motor. For
very small motors, this type of relay is simply a bimetallic element that operates within a
heater unit.

Thermal Locked-Rotor (L/R) Protection
Thermal L/R protection, similar to O/L protection, involves the matching of a relay to the
motor’s thermal capability curve. A motor with a locked-rotor condition is particularly
vulnerable to damage because of the large amount of heat generated (I2R). Also, a motor at
standstill cannot dissipate the heat as well as a motor that is rotating.
Fault Protection
As with thermal protection, the size of the motor and the type of service will influence the
type of fault protection that is required to protect the motor. Although NEC Article 430-52
and Table 430-152 dictate phase and ground fault protection for low voltage motor circuits,
the type of protective device is a designer’s choice. There are five types, each having
different benefits depending on the size of the motor, cost of protection, etc. The five types
used for low voltage motor protection are the following:
• non-time delay fuses (non-current limiting)
• time delay fuses (current limiting)
• inverse time circuit breakers
• magnetic only circuit breakers
• motor circuit protectors (MCPs)
Phase Faults
SAES-P-114 specifies magnetic-only MCCB or MCP fault protection for low voltage motors
that are rated less than or equal to 75 kW (100 hp) and low voltage power circuit breaker
(LVPCB) protection for low voltage motors that are rated above 75 kW.
Molded Case Circuit Breakers (MCCBs) are a class of breaker that is rated at 600 volts and
below. MCCBs consist of a switching device and an automatic protective device that is
assembled in an integral housing of insulated material. These breakers are capable of clearing
a fault more rapidly than LVPCBs. Solid-state trip units incorporated into some styles of
MCCBs provide for their coordination (selectivity) with LVPCBs. MCCBs are generally
sealed to prevent tampering, which in turn precludes any inspection of their contacts. MCCBs
are generally not designed to be maintained in the field, and manufacturers recommend total
replacement if a defect appears.

MCCBs are available in several different types. The thermal-magnetic type, the most widely
used, employs thermal tripping for overloads and magnetic tripping for short circuits. The
magnetic type employs only instantaneous magnetic tripping for cases where only short
circuit interruption is required. The integrally- fused type combines regular thermal-magnetic
protection together with current limiting fuses to respond to applications where higher short
circuit currents are available.
Motor Circuit Protectors (MCP) are a specific class of MCCB that has a special adjustable
instantaneous trip circuit designed primarily for motor short circuit protection. A major
feature of the MCP is that it can respond to the occurrence of low level faults in motor
windings, and it can typically clear them in less than one cycle. SAES-P-114 permits MCP
use for low voltage motor protection for motors that are rated 1 to 100 horsepower (0.75 to
75 kW). Figure 30 illustrates an MCP protecting a 75 kW, 460-volt motor.
Low Voltage Power Circuit Breakers (LVPCB), like MCCBs, are rated 600 volts and
below. They differ, however, because they are typically open-construction assemblies on
metal frames, with all parts designed for accessible maintenance, repair, and ease of
replacement. They are intended for service in switchgear compartments or in other enclosures
of dead front construction. Tripping units are field-adjustable and include electromagnetic,
direct acting, and solid-state types. They can be used with integral current limiting fuses to
meet interrupting requirements up to 200 kA RMS symmetrical. SAES-P-114 specifies the
use of LVPCBs for fault protection for low voltage motors that are rated greater than 100
horsepower (75 kW).

Figure 30. MCP Protection

Ground Faults (Greater Than 30 Horsepower)
SAES-P-114 requires ground fault protection for all low voltage motors that are rated 22.5
kW (30 hp) and larger.
Residual - The residual connection (Figure 31), although commonly used in industry for main
and feeder ground fault protection , is not typically used for motor ground fault protection,
because it is not as sensitive as the preferred zero-sequence ground fault protection method.
Figure 31. Residual Ground Fault Protection

Zero-Sequence - The zero-sequence connection is the preferred ground fault protection

scheme. Low voltage motors use a static trip (solid-state) device to trip the breaker. Note:
Saudi Aramco typically specifies zero-sequence CTs for ground fault protection. Figure 32
shows the zero-sequence connection for protecting a low voltage motor. Figures 33 and 34
show alternate connection schemes, with the zero-sequence CT connection being the
preferred Saudi Aramco connection scheme.
Figure 32. Zero-Sequence Feeder Breaker

Figure 33. Three-Wire Circuit
Figure 34. Four-Wire Circuit

Undervoltage Relay Protection (Greater Than 100 Horsepower)
The primary purpose of undervoltage relay protection (Device 27) in Saudi Aramco
applications is as a backup device for motor thermal protection (Devices 49 or 51). Because
power (I2R) is directly proportional to the current squared, and any decrease in voltage
(Figure 35) results in an increase in current, Device 27 will eventually remove the motor if
Devices 49 or 51 fail, although some damage may occur as a result of the increased
temperature (approximately 17 percent for just 10 percent low voltage).
Figure 35. Effects of Voltage Variation

Protection Scheme One-Line Diagrams
Horsepower Categories of Protection
SAES-P-114 (Chapter 6) very clearly lists the preferred protection scheme for the various
types of induction motors that are used in Saudi Aramco industrial applications. Figures 36,
37, and 38 are one-line diagrams developed to describe the SAES-P-114 motor protection
requirements. Motor protection is separated based on the following motor horsepower
ratings:
• 0.75 kW (1.0 hp) or less
• Greater than .75 kW to 75 kW (1.0 to 100 hp)
• Greater than 75 kW (100 hp)
0.75 kW (1.0 hp) or Less - This category of motor protection requires use of thermal-
magnetic molded case circuit breakers (MCCB) with three-pole thermal-magnetic trips
(Figure 36a), or combination controllers with overloads, a contactor, and a magnetic-only
MCCB or thermal-magnetic MCCB, as shown in Figure 36b.
Figure 36. Protection: 0.75 kW (1.0 hp) or Less

Greater than 0.75 kW to 75 kW (1.0 to 100 hp) - This category of motor protection permits
use of motor circuit protectors (MCP), and it requires window-type CT ground fault
protection for motors that are rated 22.5 kW (30 hp) and larger. Overload and contactor
requirements are the same as the less than 0.75 kW (1.0 hp) motor protection category. The
one-line diagram for this motor protection category is described in Figure 37.
Figure 37. Protection: Greater Than 0.75 kW to 75 kW (1.0 to 100 hp)

Greater Than 75 kW (100 hp) to a Maximum of 185 kW (250 hp) - This category of motor
protection requires use of a low voltage power circuit breaker (LVPCB), drawout type,
electrically-operated, with a shunt-trip device. Undervoltage protection (Device 27), in
addition to ground fault protection (Device 50GS), is required for the larger, low voltage-rated
motors. SAES-P-114 permits individual or common bus undervoltage protection, as shown in
Figure 38.
Figure 38. Protection: Greater Than 75 kW (100 hp)


SELECTING LOW VOLTAGE COMBINATION MOTOR STARTERS
Note: Work Aid 1 has been developed to teach the Participant the procedures to select low
voltage combination motor starters.
Introduction
To properly select low voltage motor starters, it is important to first know and understand the
common enclosure components for motor starters, their physical arrangements, the types of
enclosures available for selection, and the NEMA enclosure classification system. Following
the selection of the type and class of enclosure for the motor starter, the remaining factors that
must be selected include the overload relay, the contactor, and the disconnect/fault protective
device.
Motor Starter Components
As illustrated in the diagram shown in Figure 39, alternating current (ac) motor starters have 5
major functional components. These functional components include motor overload (O/L)
protection, motor controller, short circuit, and ground fault protection, motor circuit
disconnecting means, and an enclosure.
Overload (O/L) Protection
One of the most important components common to all motor starters is the overload (O/L)
device that is used to provide running overload protection for the motor, its control circuits,
and the connecting circuit conductors. Selection and sizing of this device is guided by
specific NEC Article 430 requirements for motor running overcurrent (O/L protection).
The definition of running overcurrent (overload) is the operating overcurrent up to and

including stalled-rotor (locked-rotor) current. Overcurrent, however, does not include fault
currents due to short circuits or grounds. When overcurrents persist for a sufficient length of
time, it causes overheating and possible damage to the motor and its circuit components. The
function of the O/L device is to monitor motor line current and to open the motor circuit when
predetermined safe levels are exceeded. In accordance with the NEC and based on specific
circuit conditions, continuous duty motors rated more than 1 hp may be protected for
overloads by means of O/L relays, integral thermal protectors, fuses, or circuit breakers. The
most commonly used overload device is the O/L relay.

Figure 39. Major Functional Components of a Motor Starter

Two types of O/L relays that respond to the heating effect of the motor line current are the
thermal and the solid-state O/L relays. The thermal O/L relay uses the motor line current to
produce heat within itself at a designated rate that simulates load and conductor heating. On
the other hand, the solid-state O/L relay monitors motor line current and it uses semiconductor
circuits to determine the heating effects that the level of current will have on the motor and its
supply conductors. The motor starter in Figure 39 shows an example of a thermal O/L relay
that is being used for overload protection, and Figure 40 shows a typical three-pole thermal
O/L relay.
Figure 40. Typical Three-Pole Thermal Overload Relay
All thermal O/L relays have an operating memory. Operating memory means that the relays
respond as if they remember that the load they are protecting has been operating at some rate,
and that it may not be cold when returned to service after an overload. Some types of solid-
state O/L relays have an equivalent operating memory to keep track of the accumulated
overload duty. This equivalent operating function can be provided in various ways, such as
by charging a capacitor, or by altering the count in a register of a microprocessor.
As illustrated in Figure 1, O/L relays are connected on the loadside of the magnetic contactor.
Each relay has two parts. One part is the thermal sensing element, often referred to as the
heater, and the other part is the overload relay contact. The thermal sensing element is
directly acted on by the line current drawn by the motor. If the motor load current exceeds
the rated value of the thermal element for a specified length of time, the relay reacts to open
the overload contacts, which in turn breaks the control circuit power to the starter coil and
shuts down the motor. The time-current characteristics of the O/L relay ensure that the motor
is automatically shut down before an overload can persist to the point where the motor
becomes overheated and damaged.

Controller
A major component common to all ac motor starters is the controller. The controller consists
of the contactor that carries the motor line current and the control circuit for the contactor.
When the O/L relays (described in the preceding section) are added to the controller, the
assembly is referred to as a basic magnetic motor starter.
The contactor portion of the controller is essentially an on-off device operated by

electromagnetic means. When the controller coil is energized through a control circuit, the
resulting magnetic field mechanically forces the main contacts to close, which starts the
motor. The coil is continuously energized to hold the contacts closed and to keep the motor
running. When the coil is deenergized, the main controller contacts are forced open by either
spring pressure or gravity, which stops the motor. Figure 41 illustrates the arrangement of the
current carrying contacts, coil, and moving armature for one pole of a contactor. Contactors
are typically designed in two, three, four, and five-pole configurations. Figure 41 also shows
that the flow of power for the contact arrangement is in a straight line, into the line side of the
assembly and out of the load side. This straight-line feature, common in most controllers, is
referred to as “straight-through wiring”. Figure 39 illustrates a controller that uses a 3-pole
magnetic contactor to make up the full-voltage, non-reversing ac motor starter. A typical
three-pole magnetic contactor is illustrated in Figure 42.
Figure 41. Typical Three-Pole Magnetic Contactor

Figure 42. Contact Arrangement for One Pole of a Typical Controller
The contactor portion of the controller must be able to continuously carry the full-load
current, and to safely interrupt the locked-rotor current of the motor being controlled. If the
motor stalls, or if it does not start properly (i.e., jammed), the current drawn by the motor
under these conditions is referred to as the locked-rotor current. This locked-rotor current is
typically
400-600% of the full-load current of the motor.
Because both the full-load and locked-rotor currents are a function of the motor horsepower
rating at a specified voltage, motor controllers are rated for the maximum horsepower that
they can safely handle at these voltages. Horsepower ratings for low voltage controllers
(NEMA sizes 00 through 9) are listed in NEMA Standard ICS-2. SAES-P-114 requires that
motor controllers be applied in accordance with their horsepower rating.
Fault Protection
Another of the major components that is common to all ac motor starters is the device that is
used to provide protection against short circuit and ground faults. The devices used for fault
protection are typically an instantaneous (magnetic-only) trip circuit breaker, an inverse time
circuit breaker, an MCP, non-time delay fuses, or dual element (time-delay) fuses. The
example motor starter illustrated in Figure 39 shows that either non-time delay fuses or an
inverse circuit breaker can be used for the short circuit and ground fault protection.

SAES-P-114 requires that only circuit breakers or MCPs be used for the fault protection
function. When circuit breakers or MCPs are used, they serve as two components for the
motor starter. First, they serve as the phase and ground fault protection device, and second,
they serve as the disconnecting device.
The fault protection device must provide protection for the complete motor branch circuit,
which includes the circuit conductors, the control apparatus, and the motor. To provide for
safe and effective sizing of the fault protection device, the NEC defines the requirements and
the maximum ratings. The first requirement for the fault protection device is that it be
capable of carrying the starting current of the motor without opening the circuit. The second
requirement is that the rating or setting of the device not exceed maximum values that are
listed in NEC
Article 430-152.
Disconnect
Another major component that is common to all ac motor starters is the disconnecting device.
In accordance with the NEC, motors and controllers must be provided with a means of safely
disconnecting them from their source of supply, such that the maintenance of the controller,
the motor, and its driven equipment can be accomplished without any hazard to personnel.
The devices that are permitted by the NEC to be used for disconnect purposes include circuit
breakers, motor-circuit switches, and molded case switches (non-automatic circuit
interrupters). A motor-circuit switch is a horsepower-rated switch capable of interrupting the
maximum overload current of a motor. A molded case switch (nonautomatic circuit
interrupter) is a circuit breaker-like device without the overcurrent element and automatic trip
mechanism. Based on its ampere rating, it is rated in amperes and it is suitable for use as a
motor circuit disconnect.
The disconnect, additionally, must open all the ungrounded supply conductors, and also be
gang-operated so that the one operating mechanism opens all poles simultaneously. The
device must give a clear indication of its status, “open” or “closed”, it must be rated in
horsepower, and it must be capable of interrupting the locked-rotor current of a motor of the
same horsepower rating. The horsepower rating is required in the event that a motor stalls,
and the motor controller fails to properly open the circuit.
With regard to location, the disconnecting means must be located in sight from the controller,
the motor location, and the driven machinery location. In addition, the disconnect must be
capable of being locked in the open position.

The NEC requires that a switch, circuit breaker, or other device serve as a disconnecting
means for both the controller and the motor to provide safety during maintenance and
inspection shutdown periods. The disconnecting means also disconnects the controller;
therefore, it cannot be a part of the controller. However, separate disconnects and controllers
may be mounted on the same panel or contained in the same enclosure. This type of
arrangement is referred to as a combination starter, and it is the most common arrangement
used in motor control centers.
Enclosure
A final component common to ac motor starters is the enclosure. An enclosure is a

surrounding case that is constructed to provide a degree of protection to personnel against
incidental contact with the enclosed equipment, and to provide a degree of protection to the
enclosed equipment against environmental conditions. Although other types of materials (e.g.,
polymeric) are sometimes used, enclosures are typically sheet metal or cast metal
construction. However, in all cases, only material that will not support combustion in air is
selected for enclosures.
In many cases, the controller and the overload relay are contained in the same enclosure. For
some types of motor starters, the disconnecting means and/or the branch-circuit fault
protective device are also included in the enclosure with the controller and overload relays.
When all of the elements (devices) are in the same enclosure, the assembly is referred to as a
combination motor starter.
NEMA Enclosure Classification System
NEMA Types
NEMA standard 250 provides a classification system for enclosures of electrical equipment.
The primary purpose of the classification system is to permit potential users to determine the
type of enclosure appropriate for the application, the features that the enclosure is expected to
have, and the tests applied to the enclosure to demonstrate its conformance to the description.
The system provides for enclosures to be designated by a “Type” number that indicates the
environmental conditions for which the enclosure is suitable. Applicable type numbers that
are for nonhazardous application include Types 1, 2, 3, 3R, 3S, 4, 4X, 5, 6, 6P, 7, 8, 9, 10, 11,
12, and 13. Type numbers that are applied to enclosures for hazardous location use include
Types 7, 8, 9, and 10. Enclosures covered by this classification system are nonventilated,
except that Types 1, 2, and 3R enclosures may be either nonventilated or ventilated. Note:
This Information Sheet will only describe NEMA Types 1, 12, 3R, 4/4X, and 7 enclosures.

NEMA 1 - General Purpose Enclosures - A NEMA Type 1 enclosure is intended for

general purpose indoor applications, and it is used primarily to provide a degree of protection
against falling dirt in locations where unusual service conditions do not exist. When properly
installed, Type 1 enclosures:
• Prevent the insertion of the end portion of a straight rod of specific diameter
into the equipment cavity of the enclosure.
• Provide a degree of protection against limited amounts of falling dirt.
• Provide suitable rust protection.
A similar, but different, classification system for enclosures is provided by the International
Electrotechnical Commission (IEC) in standard IEC-529. Figure 43 shows a comparison of
the two enclosure classifications, and it provides for conversion from NEMA-type numbers to
IEC-classifications. Figure 43 cannot be used to convert from IEC-classifications to
NEMA-type numbers because the tests and evaluations between the two systems are not
identical. With reference to Figure 43, an IEC enclosure classification of IP10 represents a
conversion of a NEMA Type 1 enclosure, which means that the NEMA Type 1 meets or
exceeds the test requirements of the IEC IP10 enclosure.
NEMA 3R - Rain-Resistant Enclosures - A NEMA Type 3R enclosure is intended for

outdoor applications and is used primarily to provide a degree of protection against rain and
sleet. This type of enclosure is not intended to provide protection against such conditions as
internal condensation or internal icing. When completely and properly installed, Type 3R
enclosures:
• Prevent water from contacting live parts, insulation, and wiring under test
conditions that are intended to simulate rain.
• Are undamaged after being encased in ice under test conditions.
• Prevent the insertion of the end portion of a straight rod of specific diameter
into the equipment cavity of the enclosure.
• Require the use of a tool to gain access to the equipment cavity or have
provisions for locking.
• Are permitted to have a conduit hub or equivalent provision to exclude water at

the conduit entrance if the entrance is above the lowest live part.
• Have provisions for drainage.
• Have suitable rust protection.

NEMA 12 - Dust-Tight Industrial Enclosures are intended for indoor applications used
primarily to provide a degree of protection against circulating dust, falling dirt, and dripping
noncorrosive liquids. This type of enclosure is not intended to provide protection against
such conditions as internal condensation.
NEMA Enclosure IEC Enclosure

Type Number Classification Designation
1 IP10
2 IP11
3 IP54
3R IP14
3S IP54
4 and 4X IP56
5 IP52
6 and 6P IP67
12 and 12K IP52
13 IP54
(Reference NEMA Standard Publication No. 250)
Notes: 1. This comparison is based on tests specified in IEC Publication

529.
2. It cannot be used to convert IEC Classification Designation to
NEMA-Type Numbers.
Figure 43. Conversion of NEMA-Type Numbers to IEC Classification
When completely and properly installed, Type 12 enclosures:
• Prevent the entrance of water under test conditions intended to simulate an

environment of light splashes, seepage, and dripping of noncorrosive liquids.
• Exclude dust under test conditions that are intended to simulate an indoor
industrial environment of circulating dust, lint, nonignitable fibers, and
noncombustible flyings.

• Have no knockouts or unused openings.
• Have doors with provisions for locking or the requirement that a tool be used to
gain entry. All closing hardware is captive.
• When intended for wall mounting, they have mounting means external to the
equipment cavity. When intended for floor mounting, they have closed
bottoms.
• Have gaskets, if provided, that are oil-resistant.
• Have suitable rust protection.
NEMA 4/4X - Water, Dust-Tight and Corrosion-Resistant Enclosures are intended for
indoor or outdoor applications. Both types are used primarily to provide a degree of
protection against windblown dust and rain, splashing water, and hose-directed water. In
addition, the Type 4X enclosure is also intended to provide a degree of protection against
corrosion. These types of enclosures are not intended to provide protection against such
conditions as internal condensation or internal icing. When completely and properly installed,
Type 4 and 4X enclosures:
• Exclude water under test conditions that are intended to simulate a hosedown
condition.
• Are undamaged after being encased in ice under test conditions.
• Are permitted to have a conduit hub or an equivalent provision to exclude

water at the conduit entrance.
• Have mounting means, if provided, that are external to the equipment cavity.
In addition to the above features, Type 4 enclosures have suitable corrosion protection, and
Type 4X enclosures, in order to provide a degree of protection against specific corrosion
agents, are made of American Iron and Steel Institute Type 304 Stainless steel, polymerics, or
materials with equivalent corrosion resistance.
NEMA 7 - Hazardous Location Enclosures are intended for indoor use in hazardous
locations classified as Class 1, Group A, B, C, or D, as defined in NEC. When properly
installed and maintained, NEMA 7 type enclosures are designed to contain an internal
explosion without causing an external hazard.

Type 7 enclosures are designed to be capable of withstanding the pressures resulting from an
internal explosion of specified gases and to sufficiently contain the explosion to the extent
that an explosive gas-air mixture existing in the atmosphere surrounding the enclosure will
not be ignited. Additionally, Type 7 enclosures are designed such that heat generating
devices contained within the enclosure will not cause external enclosure surfaces to reach a
temperature capable of igniting explosive gas-air mixtures in the surrounding atmosphere.
When completely and properly installed, Type 7 enclosures:
• Provide a degree of protection to a hazardous gas environment from an internal

explosion or from operation of internal equipment.
• Do not develop, when equipment is operated at rated load, surface temperatures

that exceed prescribed limits for the specific gas corresponding to the
atmospheres for which the enclosures are intended.
• Withstand a series of internal explosion design tests that determine the

maximum pressure effects of the gas mixture and propagation effects of the gas
mixture.
• Withstand, without rupture or permanent distortion, an internal hydrostatic

design test based on both the maximum internal pressure obtained during
explosion tests and the specified safety factor.
• Are marked with the appropriate Class and Group(s) for which they have been
qualified.
Common Enclosure Components
Motor starter enclosures have several components that are common to all types of enclosures.
These components include a disconnecting means, lock and tag features, and enclosure
interlocks.
Disconnecting Means - A common component that is included on all types of enclosures is a

means of externally operating the disconnect device that is mounted inside of the enclosure.
This component is typically a flange-mounted handle located on the outside of the enclosure,
as shown in Figure 44. The handle is mechanically fastened to an operating mechanism that
is located inside of the enclosure and that attaches to the disconnecting device (disconnect
switch or breaker). The handle provides for external operation of the disconnecting device,
and it gives positive visual indication of its status (open or closed).

Lock and Tag Features - A common component of enclosures that is very important for
safety is the provision to padlock the operating handle. This provision allows one or more
padlocks to be inserted through a hole in the operating handle to lock it in the “Off” position.
The purpose of this feature is to allow the motor starter to be locked in the de-energized
position and tagged with a “Warning” tag to provide for safe inspection and maintenance of
the motor. The location of this locking provision is identified for the enclosure shown in
Figure 44. In addition to the capability of padlocking the operating handle, enclosures also
allow padlocking of the cover to prevent access by unauthorized personnel.
Interlocks and Latches - Another set of components that are common to all types of
enclosures is the cover safety interlock. The typical enclosure has two interlocks. These
interlocks are illustrated in Figure 44. One interlock is connected between the external
operating handle and the enclosure cover to prevent opening of the cover while the handle is
in the “On” position. In order to open the cover, the handle must be moved to the “Off”
position. However, to allow access by trained and authorized personnel for purposes of
special maintenance, an interlock bypass is usually provided by the manufacturer.
The second interlock is designed to function when the cover is open. This interlock prevents
the breaker or disconnect switch from being operated in the “On” position while the cover
remains open. The one exception to the operation of this interlock is that trained and
authorized personnel are provided the option of activating the interlock bypass.
Figure 44. Common Enclosure Components

Enclosed Type Starters
Single or Group Wall Mount - The single wall-mount enclosure is the most commonly used
type of enclosure. A typical single enclosure, similar to the one illustrated in Figure 45, offers
the advantage of placing individual starters at their most convenient location, while still
providing all of the common component features described above (i.e., disconnecting means,
lock and tag features, and enclosure interlocks).
Single wall-mount enclosures are also designated by a NEMA-type number that indicates the
environmental conditions for which they are suitable. Single wall-mount enclosures are
available from manufacturers in a number of sizes. The required size for an enclosure is
recommended by the manufacturer and it is determined by the type and size of combination
controller to be housed. When needed, extra space can be requested by the user to
accommodate field-mounted control components.
Figure 45. Single Wall-Mount Enclosure

A group wall-mount enclosure is essentially several single enclosures designed and

manufactured as one unit, but with individual internal compartments. The group-type
enclosure is designed to save time, space, and expense when installing multiple control
devices.
Group enclosures are typically partitioned into either four or six compartments. Each
compartment is designed to hold a combination starter, incoming or feeder circuit breakers,
fusible switches, or other auxiliary devices. The barriers between compartments can be
removed to provide oversize spaces that allow for installation of a lesser number of larger size
controllers.
In addition to the barrier compartments, the group enclosure normally contains internal wiring
troughs. Typically, one trough is located at the top and is fitted with power terminal straps for
extension to adjoining compartments. Another wiring trough is located along the bottom for
interconnecting wiring and outgoing cables.
The compartments have hinged doors that are interlocked to prevent opening when the
breaker switch is in the “On” position. In addition, the disconnect operating mechanism can
be padlocked in either the “On” or “Off” positions.
Motor Control Centers (MCC’s) - A motor control center (MCC) is a group of combination
starters assembled into a single metal enclosure with individual compartments for each starter.
Control centers are arranged in straight-line, L-shaped, or back-to-back configurations.
Figure 46 shows a typical arrangement of a motor control center in a straight-line
configuration.

Figure 46. Typical Low Voltage Motor Control Center (MCC)

The metal enclosure of the MCC is built with a single steel-channel frame that has
compartment-like spaces for insertion of individual combination starters. The individual
compartments of the enclosure share common bus systems and wireways. A main horizontal
bus is installed across the top of the unit to provide three-phase power distribution from the
incoming line or primary disconnect device to each vertical structure. A vertical bus is
mounted in each vertical unit to provide distribution of the main bus power to each of the
individual vertical compartments. Completing the arrangement of bus systems is a neutral
bus mounted on stand-off insulators across the bottom of each vertical unit and a ground bus
mounted across the top of each unit. The enclosure has both vertical and horizontal wireways
to provide for convenient servicing and controller change-outs. All wireways are provided
with hinged panel covers for easy access and as a barrier to fire.
For an MCC type enclosure, a steel compartment shell, referred to as a drawout unit or case,
is provided for each compartment. Figure 47 shows the construction of a typical drawout
case. The drawout case, comprised of three sides and a base, serves as a housing for
mounting of each starter. Four mounting points on the drawout case allow it to engage guide
rails, located near the top of the compartment space, for easy insertion and withdrawal. After
insertion, a quarter turn latch located at the top of the case securely holds the drawout unit in
the compartment.
Figure 47. MCC Drawout Unit

Figure 48 shows the arrangement of a typical handle mechanism that is located on the front of
a drawout case. The handle mechanism is designed to operate the controller disconnecting
device that is located inside of the drawout case. Similar to other types of enclosures, the
handle mechanism for this enclosure provides common safety features. These safety features
include an interlock that prevents the compartment door from being opened when the handle
is in the “On” position. When the compartment door is open and the handle is in the “On”
position, an interlock prevents the drawout case from being removed from the compartment.
Additionally, the handle mechanism can be padlocked in the “Off” position to ensure that
individual starters are not energized accidentally or by unauthorized personnel during
maintenance procedures.
In addition to the handle mechanism, a control panel is mounted on the front of the drawout
case. The control panel allows mounting of pushbuttons, indicator lights, and related control
devices. The arrangement of mounting both the handle mechanism and the control panel on
the front of the drawout case helps to make inspections and maintenance easier. A final
feature of this type of enclosure is the compartment door. Each compartment of the motor
control center has a separate hinged door that allows the handle mechanism and control panel
to protrude through the door when it is closed. The doors are typically secured in the closed
position by means of two quarter-turn indicating type fasteners. As described above, an
interlock prevents the door from being opened when the handle is in the “On” position.
Figure 48. Handle Mechanism Locked-Out With Padlock

Saudi Aramco Applications
SAES-P-114 requires that a motor controller be either a combination motor starter or a circuit
breaker. When the controller is a combination motor starter, the enclosure for the controller is
provided by the manufacturer as an integral part of the starter. The provided enclosure is
designed and assembled in accordance with NEMA Standards 250 and ICS-6 to meet specific
application environmental conditions. The enclosure provided by the manufacturer also
includes the common enclosure components described above (a disconnecting means, lock
and tag features, and enclosure interlocks).
If the controller is a circuit breaker, it is designed and constructed with a self-encasing

enclosure, or the breaker is designed for mounting inside of a metal-enclosed switchgear
compartment.
16-SAMSS-503.4.2 requires that low voltage MCC’s be rigid, free-standing, metal-enclosed
structures, consisting of vertical sections assembled into a group having a common bus and
forming an enclosure to which additional sections may readily be added. The enclosures must
be suitable for back-to-wall or back-to-back mounting. Back-to-back constructions that have
a common horizontal bus are not acceptable. The MCC cubicle design must be NEMA Class
1, Type B, with all ventilation openings suitably filtered or screened with a specified
corrosion-resistant material that is arranged to prevent entrance of rodents and other foreign
matter.
Overload Relay (O/L) Selection Factors
Overload relays are protective devices that guard low voltage ac motors against a variety of
abnormal conditions that can overheat motor windings. The O/L relays are designed to
accomplish this abnormal condition protection by reflecting the heating characteristics of the
motors that they protect. The two main components of an O/L relay are the relay itself and
the heater element. When selecting an O/L and its heater elements for application, several
factors must be considered. These factors include the motor full-load current and service
factor, and the relay class, type, and temperature criteria. This Information Sheet describes
these overload relay selection factors. Note: Work Aid 1G has been developed to teach the
Participant procedures to select an O/L relay.

Motor Data
Horsepower is the rated output mechanical power that may be applied to the motor shaft. IEC
motors are rated based on output kilowatts (kW) and NEMA MG-1 motors are rated based on
output horsepower (hp), where 1 hp equals 0.746 kW. For example, a NEMA MG-1 rated
100 hp motor is equivalent to a nominal 75 kW (74.6 kW actual) IEC-rated motor.
Full-Load Current is the most important factor that is used in the selection of the overload
relay. The current (amperes) marked on the motor nameplate represents the amount of
amperes that the motor will draw continuously, when delivering its nameplate-rated
horsepower at nameplate-rated voltage and frequency. When an O/L relay is applied to a
motor circuit, it senses the motor line currents, either directly or indirectly. Where the O/L
relay senses the current directly, the motor amperes flow directly through the relay and its
heater elements. Where the overload relay senses the current indirectly, the motor amperes
flow through the primary winding of a current transformer (CT), and the O/L relay senses the
current via the secondary winding of the CT.
Because O/L relays sense the line currents of a motor, they are sized according to the amount
of amperes that they are capable of handling. Each size of relay is rated with a range of
amperes that it can safely and continuously carry. When selecting an O/L relay, the selected
size must have a current range that covers the full-load nameplate amperes of the motor to
which it is applied.
In addition to selecting the O/L relay, the motor nameplate full-load amperes are also used to
select the heater elements that are mounted in the relay block. The heater elements are in
series with the power conductors of the relay, and they use the full-load amperes to generate
and provide the heat that operates the bimetallic contact in the relay. Similar to the O/L,
heater elements are sized and selected according to a range of full-load amperes for which
they are designed.

Service Factor (S.F.) is another factor that is used in the selection of the O/L relay. In
accordance with NEMA MG-1, the service factor of an ac motor is a multiplier, which when
applied to the rated horsepower, indicates a permissible continuous horsepower loading for
the motor. When the voltage and frequency of a motor are maintained at nameplate values,
the motor may be loaded up to a horsepower rating that is obtained by multiplying the rated
horsepower times the service factor. Note: Saudi Aramco standards only specify 1.0 S.F.
motors. The service factor is used in determining the maximum trip rating for the O/L relay.
In accordance with NEC Article 430, the O/L relay must be selected to trip, or it must be rated
at no more than the percent of motor nameplate full-load amperes, as listed in Figure 49.
Motor Parameter Percent of Motor Nameplate

Full-Load Amperes (FLA)
Motors with S.F. > 1.15 125%
Motors with temperature 125%

rise < 40oC
All other motors 115%
Figure 49. Maximum Overload Relay Trip Rating Based on

Motor Service Factor (S.F.)

Types
Bimetallic O/L Relays have two basic components: the relay itself, which contains the
bimetallic actuated contact, and the heater elements (Figure 50). The relay is available as
either a single-pole relay or a three-pole (block) relay. The heater element is constructed of
resistance wire or similar material, which is mounted inside of the relay body.
Figure 50. Bimetallic Type Overload Relay
Block-type O/L relays are three-pole bimetallic, thermally actuated relays. The physical
construction of the block-type relay includes three sets of motor current-carrying connection
terminals mounted on an insulated housing. Provisions for inserting and connecting
interchangeable heater elements are contained within the insulated housing (body) of the
relay. The relay provides a circuit that allows motor current to flow into the relay connection
terminals, through the heater elements, and back out to the motor circuit. A bimetallic strip
that is used to detect the heat generated by the interchangeable thermal elements is also
contained within the insulated housing (body) of the relay. The bimetallic strip operates a
single-pole, single-throw, snap-action switch. The snap-action switch is used to open the
control circuit (NC O/L contact) of the starter.

The block-type relay is rated in accordance with the range of full-load current that it is
capable of carrying, the NEMA size of contactor that it connects to, and the interchangeable
heater elements that are designed for use with the relay.
Heater elements are constructed of resistance wire or of similar material. They are designed
to be inserted into the O/L relay. Each block-type relay is constructed with three individual
compartments to accept three individual heating elements. The heaters are connected to the
relay in an arrangement that allows the motor current or CT secondary current to flow directly
through them.
Each manufacturer has its own form of designating the heater’s range and ratings. The
precise heater element current rating depends on many factors, such as the number of heaters
included in the O/L relay, and the type of enclosure that is used for the starter. However, in
all cases, heaters are rated based on a range of motor amperes at which they will generate
sufficient heat to cause the O/L relay to operate. Typically, the heater(s) selected will provide
for the overload relay to operate at 115% to 125% of the heater’s rating at an ambient
temperature of 400C.
The operation of the bimetallic type O/L relay shown in Figure 50 is in a straight or unflexed
state when it is relatively cool (e.g., when current through the heater is below the rating of the
heater). In this position, the normally closed (NC) O/L contact mechanically connected to the
bimetallic strip is in its normal (closed) state. With the terminals of the heater connected to
the motor circuit, motor current flows through the heater. As current flows, the power
consumed by the heater (I2R) is converted to heat that acts directly on the bimetallic strip. In
accordance with the inverse time versus current curve for the O/L relay, when the motor
current becomes excessive for a sustained period of time, the heat from the heater element
will cause the bimetallic strip to deflect and operate the NC O/L contact. Opening the O/L
contact, in turn, opens the coil circuit to the starter.
Solder-Pot O/L Relays - Solder-pot overload relays are thermally responsive relays that
contain two basic components: a ratchet mechanism that operates an NC O/L contact and a
heater element (Figure 51).
The ratchet mechanism is comprised of several parts. One part is a small cylinder that
contains an alloy (e.g., solder) that will melt due to the heat produced by excessive current
flow in the motor. Within this cylinder is a portion of a shaft that is prevented from turning
by the holding action of the alloy. Another part on the other end of the shaft is connected to a
toothed ratchet wheel that interlocks with a pawl and that holds a spring-loaded actuator in the
loaded position. At the end of the actuator travel path is an NC O/L contact that is operated
when the actuator is released and allowed to reach the end of its travel path.

The heater element for a solder-pot O/L relay is designed in the form of a resistance wire coil
that mounts around the cylinder containing the alloy. Similar to the heater elements that are
used for the bimetallic type relay, the heater elements for the solder-pot relay are designed to
produce a precise amount of heat in direct proportion to the motor current that flows. The
heater elements are rated in accordance with a range of motor current that will cause the
overload relay to operate when excessive motor current flows for a specified period of time.
The characteristics of the heater cause the O/L relay to operate with an inverse time-current
characteristic.
When the O/L relay is connected for operation, its heater terminals are connected to the motor
circuit, which allows motor current to flow through the heater. The alloy in the cylinder is a
solid material, which allows the ratchet to hold the actuator in place. When an excessive
amount of current flows through the heater for a specific amount of time, the heat generated
by the heater element acts directly on the alloy film, melting it at a precise temperature. Once
the alloy melts, the shaft within the cylinder is released, which allows it to turn and rotate the
ratchet wheel. Rotation of the wheel releases the pawl, which in turn releases the spring-
loaded actuator. The released actuator then travels to the NC O/L contact and operates it to
open the coil circuit of the starter.
Figure 51. Solder-Pot Type Overload Relay

Solid-State O/L Relays monitor motor line current by use of semiconductor circuits to
determine the heating effects that the level of current will have on the motor and its
conductors. The basic components of a solid-state relay are the main body (or block) and a
selection of current sensing and special function plug-in modules. The main body (or block)
of the solid-state O/L relay is physically constructed to hold three sets of motor current-
carrying connection terminals mounted on an insulated housing. When placed in operation,
the terminals are connected to the motor circuit to allow motor current to flow through the
relay. Contained within the relay body are built-in current transformers that are used to
monitor the motor line currents and to translate them into logic level signals. Also contained
within the body of the relay is a semiconductor circuit that represents a thermal model of the
motor. The thermal model is typically calibrated to have an exponential function with NEMA
O/L relay Class 10 characteristics.
The main body of the relay provides for mounting of selected plug-in modules to build in the
amount and type of protection desired. The selection of plug-in modules include current
sensing modules and special function modules. The main body of the relay also houses an
electromechanical relay contact that is used for opening the coil circuit of the starter. This
contact is normally provided as a single-pole single-throw (SPST) NC contact that is closed
when the relay is energized, and that opens when the relay trips or when control power is
removed.
In addition to the above features, the solid-state overload relay is ambient-compensated, has
both manual and automatic reset capabilities, and indicates overload trip operations through
the use of light emitting diodes (LEDs).
In place of the type of heater elements used by thermally actuated overload relays, the solid-
state relay uses a plug-in module (Figure 52) that is identified as a current sensing module.
This module, sometimes referred to as a “heater” module, receives the logic level signals that
represent the motor line current.

Figure 52. Current Sensing (Heater) Plug-In Module for

Solid-State Overload Relay
Although the current sensing plug-in module receives logic level signals and not actual motor
amperes, it is still rated in units of motor line amperes. Nominal ratings for the current
sensing plug-in module range from 0.54 amperes to 150 amperes. When a current sensing
module for the solid-state relay is selected, the selection is made in accordance with the
percent of full-load current desired to trip the overload relay. Similar to thermal type relays,
the solid-state overload relay normally provides for trip operation at 115% to 125% of motor
full-load amperes at a 400C ambient temperature.
Operation of the solid-state relay is accomplished by the CTs monitoring all three phases of
the motor current. The current signals from the CTs are transposed, via solid-state circuits, to
a logic level signal and then transmitted to the current sensing plug-in module. The plug-in
module, which also contains solid-state circuitry, receives the logic signals and, using the
thermal model circuit built into the relay, it determines the corresponding heating effects on
the motor. When the current sensing module determines that the flow of current is excessive
for a specified period of time, it sends a trip signal to the NC electromechanical relay contact
in the main relay, which operates the contact and opens the external coil circuit of the starter.
A principle advantage of the solid-state relay over the thermally actuated type relay is that the
solid-state relay operates within a one percent accuracy. The thermal type relay is not as
accurate because small variations in tolerances in the mechanical elements of a thermal relay
result in large variations in performance. On the other hand, solid-state overload relays are
more expensive than thermal types, which make them less popular for smaller, less critical
motor loads.

Classes and Types
Inverse-time O/L relays are described by time-current characteristics, and, in accordance with
NEMA ICS-2, they are designated with a class number indicating the maximum time in
seconds at which they will operate (trip), when carrying a current equal to 600% of their
current rating. The class number applies to the relay under the condition that overcurrents are
balanced in all three phases. NEMA overload relay classes include Classes 10, 20, and 30.
Figure 53 shows typical time-current characteristics for Class 20 and Class 30 type O/L
relays.
Classes 10, 20, or 30 - NEMA O/L relay classes are defined as follows:
• Class 10 - A NEMA Class 10 overload relay operates (trips) in 10 seconds or

less when carrying a balanced overload current of 600% of its current rating.


Figure 53. Typical Time-Current Characteristics for Class 20

and Class 30 Overload Relays

Types A or B - Thermally actuated bimetallic overlay relays are available as one of two
types, either Type A or Type B, described as follows:
• The Type A O/L relay is designed to protect industrial motors against overload
conditions. Using a block-type, bimetallic design, a Type A relay provides
Class 20 operation in either single or three-phase applications.
• Type A relays are provided with field-selectable manual or automatic reset

modes. The relay is typically supplied from the manufacturer set for manual
reset operation. However, it may be adjusted in the field for automatic reset.
• The Type A relay is available as either ambient-compensated or non-

compensated. Ambient-compensated relays have the advantage of providing
the same trip characteristics in ambient temperatures ranging from -400C to
+770C. Compensated and non-compensated relays are generally identified by
the color of their reset rod. Note: Saudi Aramco standards require use of
ambient-compensated O/L relays.
• For the Type A O/L relays, interchangeable thermal heater elements for single-
pole and block-type relays are available to cover motor full-load currents that
range from 0.29 to 133 amperes, in approximately 10% steps.
• Using a block-type, bimetallic design that provides Class 20 operation in either

single or three-phase applications, the Type B O/L relay is similar to the Type
A overload relay in that it is designed to protect industrial motors against
overload conditions.
• Additional similarities of the Type B with the Type A relay include: available
ambient-compensated and non-compensated models, inverse time delay trip
operation, standard SPST NC snap-action control contact, factory-available
SPDT NO-NC contacts, visual trip indicator, and available interchangeable
thermal heater elements rated to cover motor full-load currents from 0.29 to
133 amperes in approximately 10% steps. The basic differences of the Type B
relay with respect to the Type A relay are that Type B relays are furnished only
with manual reset capabilities, they have no trip adjustment knob, they provide
a mechanical trip bar to manually check the contact operation of the relay, and
they use a different reset-bar color code to indicate whether they are
compensated or non-compensated relays.

Temperature Compensation Criteria
Motor-Ambient - In accordance with NEMA MG-1, the ambient temperature rating of the
motor is the maximum temperature of the medium and gases surrounding the motor that the
motor is designed to operate in to meet its nameplate ratings. Increased ambient temperature
will cause an increase in motor operating temperature, resulting in possible thermal damage to
the motor.
NEC Article 430 requires that overload relay trip ratings be limited based on rated motor
temperature rise. In accordance with NEC Article 430, O/L trip settings are to be limited to a
maximum of 115% of motor full-load current for motors rated at a temperature rise greater
than 400C.
Starter-Ambient - The ambient operating temperature of the starter should also be

considered when selecting O/L relays. Starters operating in a constant ambient temperature
that is within the rating of the overload relay will allow the relay to operate properly. This
constant ambient temperature will provide for consistent and acceptable protection of the
motor. For constant ambient temperatures, it is not a requirement to use a temperature-
compensated overload relay.
Contactor Selection Factors
When selecting a contactor for application in a motor starter, several factors must be
considered. These factors include the type of contactor to be selected (air-magnetic or
vacuum), the size of contactor required for the application, the need of contactor auxiliary
devices for operation of the control circuit, and the proper contactor coil voltage rating. This
Information Sheet describes these contactor selection factors. Note: Work Aid 1H has been
developed to teach the Participant procedures to select a contactor.
Motor Data
Continuous Current (Amperes) - When selecting a contactor, the first factor to consider is
the continuous current rating of the contactor. In accordance with NEMA ICS-2-321, each
NEMA size contactor is designated with a continuous current rating. This rating represents
the maximum RMS current, in amperes, which the contactor (controller) is permitted to carry
on a continuous basis without exceeding the temperature rise permitted for the contactor. For
example, the maximum rated continuous current for a NEMA Size 1 contactor is 27 amperes
(Figure 54). When selecting a contactor, this continuous current rating should be compared to
the continuous full-load ampere rating of the motor.

One exception for the continuous current rating of the contactor, is the “service-limit current
rating”. The service-limit current rating represents the maximum RMS current, in amperes,
which the contactor is permitted to carry for protracted periods in normal service. At service-
limit current ratings, temperature rises are permitted to exceed those ratings that are obtained
by testing the contactor at its continuous current rating. For example, the service-limit current
rating for a NEMA Size 1 contactor is 32 amperes, as listed in Figure 54. This service-limit
current rating implies that the contactor may be used at this current level for reasonable
periods during normal service (i.e., the high-current intervals of load cycles, long acceleration
times, short periods of dynamic braking, etc.). However, it is expected that the temperature
rise of the contactor will not exceed its continuous current temperature rise.
Maximum Horsepower
NEMA Continuous 200 V 230 V 460 V Service-Limit

Size Current @ 60 Hz @ 60 Hz or 575 V Current
Rating @ 60 Hz Rating
(Amperes) (Amperes)
00 9 1.5 1.5 2 11
0 18 3 3 5 21
1 27 7.5 7.5 10 32
2 45 10 15 25 52
3 90 25 30 50 104
4 135 40 50 100 156
5 270 75 100 200 311
6 540 150 200 400 621
7 810 ----- 300 600 932
8 1215 ----- 450 900 1400
9 2250 ----- 800 1600 2590
(Reference: NEMA Standard ICS-2-321)
Figure 54. Horsepower Ratings for Three-Phase Single Speed Full-Voltage Magnetic
Contactors (Controllers) for Nonplugging and Nonjogging Duty

Horsepower - When selecting a contactor, another important selection factor to consider is

the size and rating of the contactor required for the application. In accordance with NEMA
ICS-2, contactors (controllers) are rated by means of two methods. One rating method is
based on horsepower, and the other method is based on motor full-load and locked-rotor
current. The method of rating contactors based on horsepower is the rating method that is
required by
16-SAMSS-503.4.4.
Because both the full-load and locked-rotor currents are a function of the horsepower rating at
a specified voltage, motor contactors (controllers) are rated for the maximum horsepower that
they can safely handle at these specified voltages. The motor contactors are classified by a
size number, and they are rated in horsepower. Figure 54 shows the maximum horsepower
ratings for three-phase, single-speed, full-voltage magnetic contactors for nonplugging and
nonjogging duty, as designated by NEMA. As the NEMA size classification increases, the
physical size of the contactors (controllers) increases because larger contacts are needed to
carry and break the higher motor currents, and heavier mechanisms are required to open and
close the contacts.
The NEMA size horsepower ratings shown in Figure 53 are based on the mechanical and
electrical requirements for starting a NEMA design B or C motor that has normal acceleration
time and normal start/stop duty. If greater than normal duty is required, such as motor
jogging, long acceleration time, or dynamic braking, a controller of larger than normal size is
specified.
Motor Voltage - The voltage rating required for the contactor is another factor that must be
considered when selecting a contactor. Low voltage contactors are designed for service on
circuits rated to 600 vac. However, for a given NEMA size contactor, the horsepower rating
for the contactor is dependent on the voltage level at which the contactor is applied.
Referring again to the table of horsepower ratings shown in Figure 54, for a given NEMA size
contactor, its horsepower rating is reduced when applied at the lower voltage levels. For
example, a NEMA Size 1 contactor is rated to control an ac induction motor with a maximum
nameplate rating of 10 horsepower at a nameplate voltage rating of 460 V or 575 V.
However, the same NEMA Size 1 contactor, when it is operated at a voltage of 200 vac or
230 vac, is rated to control only a 7.5 horsepower motor. When selecting a contactor, it is
necessary to use both the motor nameplate voltage and the motor nameplate horsepower for
the selection process.
Motor Contactor Types
Air-Magnetic is the most common type of contactor selected for motor starter applications.
Figure 55a shows a typical NEMA air-magnetic contactor that has an O/L relay connected to
its load terminals. Air-magnetic type contactors are generally specified because they are

economical and easy to maintain, and because they have a versatile design that provides for
accommodating a great many variations in the method of control.

The electrical portion of the contactor consists of an electromagnet, a coil, and a moving
armature or crossbar. Moving and stationary contacts, arranged in sets or poles, carry the
motor current. Air-magnetic contactors are often supplied with three poles or sets of contacts.
However, other configurations, such as two, four, or five poles are also available.
When power is applied to the contactor coil, magnetic flux is created in the electromagnet.
The magnet then attracts the armature, which pulls the moving contacts into the stationary
contacts and allows power to flow through the contacts to the motor.
The air-magnetic contactor must be able to close, carry, and open normal motor current. As a
result, the contactor is rated in accordance with the size of the load that it must control.
NEMA standards provide two methods of rating the air-magnetic contactor. One method is a
rating based on horsepower, and the other method is a rating based on motor full-load and
locked-rotor current.
Low-voltage air-magnetic type contactors are designed by NEMA (and available from
manufacturers) in sizes 00 to 9 with horsepower ratings from 1.5 hp to 1600 hp. Note:
16-SAMMSS-503.4.4 requires that air-magnetic contactors be selected based on horsepower
rating.
Vacuum - When selecting the type of contactor to use in a low-voltage motor starter, another
choice is a vacuum type contactor. Figure 55b shows a typical three-pole vacuum contactor.
The vacuum type contactor offers several advantages over air-magnetic type contactors.
These advantages include a compact, lightweight design and a long service life. The most
important of these advantages to consider is the long service life. For air-magnetic contactors,
service life is typically measured in tens-of-thousands of operations. In the case of vacuum
contactors, service life is typically measured in hundreds-of-thousands of operations.
However, a cost comparison of a vacuum contactor with an air-magnetic contactor of the
same rating indicates that the vacuum contactors cost more.
The vacuum contactor is constructed with its main contacts sealed inside ceramic tubes from
which all air has been evacuated (i.e., the contacts are in a vacuum). No arc boxes are
required, because any arc formed between opening contacts in a vacuum has no ionized air to
sustain the arc. The arc simply stops when the current goes through zero as it alternates at
line frequency. The arc usually does not survive beyond the first half-cycle after the contacts
separate. As a result of the vacuum’s limiting the amount of arcing, the rate of contact wear is
reduced and contact life is increased.

The ceramic tube with the moving and stationary tubes enclosed is called a vacuum
interrupter, or bottle. There is one bottle for each pole of the contactor. A two-pole contactor
has two bottles, and a three-pole contactor has three bottles. A metal bellows (like a small,
circular accordion) allows the moving contact to be closed and pulled open from the outside
without letting air into the vacuum chamber of the bottle. Both the bellows and the metal-to-
ceramic seals of modern vacuum bottles have been improved to the point that loss of vacuum
is no longer a cause for excessive concern.
Aside from the difference in contact and interrupting medium (vacuum versus air) design, the
vacuum contactor is used and applied in the same manner as an air- magnetic contactor. As a
result, low-voltage vacuum contactors are designated by NEMA according to the same tables
as used to size and rate air-magnetic contactors.
Figure 55a. Typical Air-Magnetic Contactor with O/L Relay

Figure 55b. Typical Vacuum Contactor

Coil Voltage Ratings
The coil voltage rating is selected to equal the voltage rating of the motor starter control
circuit. Because there are many different voltage ratings for control circuits, low voltage
contactors are available with a wide selection of ac and dc coil voltage ratings.
For ac voltage coils, manufacturers typically offer coil voltage ratings ranging from 24 vac to
600 vac. As an example, Figure 56 shows ac coil voltage ratings for NEMA Size 3 and 4
contactors. Other voltage ratings are usually available as a special order. In accordance with
NEMA Standard ICS 2-110, these ac-operated contactors must be able to withstand 110
percent of their rated voltage continuously without injury to the operating coil, and they must
close successfully at a minimum of 85 percent of their rated voltage.
NEMA Contactor Size Cont. Rating Amperes AC Coil Volts
3 90 120
3 90 208
3 90 240
3 90 480
3 90 600
4 135 120
4 135 208
4 135 240
4 135 480
4 135 600
Figure 56. Example of AC Coil Voltage Ratings for NEMA Size 3

and 4 Low Voltage Contactors

For dc voltage coils, manufacturers typically offer coil voltage ratings ranging from 24 vdc to
250 vdc. Voltage ratings offered for dc coils typically include 24, 48, 125, and 250 vdc. In
accordance with NEMA Standard ICS 2-110, dc-operated contactors must be able to
withstand 110 percent of their rated voltage continuously without injury to the operating coil,
and they must close successfully at a minimum of 80 percent of their rated voltage.
Auxiliary Devices
During the selection of a contactor, auxiliary devices are available for selection and inclusion
on the contactor. Consideration should be given to the contactor application and the control
circuit arrangement to determine if auxiliary devices are needed. Two auxiliary items that are
often considered are contacts and interlocks.
Contacts - Depending on the complexity of the control circuit to be used for the contactor
being selected, additional auxiliary contacts may be required in addition to the standard ones
provided with the contactor. For complex control circuits, manufacturers typically offer one
or more types and sizes of auxiliary contacts that can be added to the contactor. Some of
these auxiliary contacts can be assembled to the contactor in the field, while others may
require factory assembly. Figure 57 shows one type of auxiliary contact that can be added to
Size 00 through Size 1 contactors at the factory or in the field. The auxiliary contact shown in
Figure 57 can be provided as an NO or NC contact, and it can be selected with either an 18-
ampere or a 27-ampere continuous current rating.
Interlocks - When more than one contactor is to be selected for a single purpose application,
such as reversing or multi-speed applications, it is necessary to provide interlocks between the
contactors to prevent one from closing before the other has opened. When contactors are
selected for these single purpose applications, the manufacturer normally installs the required
mechanical and/or electrical interlocks at the factory. However, for some applications, it may
be necessary to separately select either mechanical and/or electrical interlocks for installation
in the field. Figure 58 shows examples of a typical mechanical interlock (Figure 58a) and a
typical electrical interlock (Figure 58b).

Figure 57. Typical Auxiliary Contact
Figure 58. Typical Auxiliary Interlocks

Disconnect/Fault Protection Selection Factors
Motor Nameplate Data
This Information Sheet will briefly review the following nameplate data to be used in
selecting a low voltage motor disconnect/fault protective device. Note: Work Aid 1I has been
developed to teach the Participant procedures to select disconnect/fault protection.
• Full-load amperes
• kVA code/locked-rotor amperes
• Voltage
• Horsepower
Full-Load Amperes - The protective device’s continuous current rating should not exceed
the motor’s full-load amperes (IFLA), as listed in NEC Table 430-150. 16-SAMSS-503
specifies that the continuous current ratings of MCCBs or (MCPs) shall not be less than 125%
IFLA unless the MCCB is 100% rated. If an LVPCB is being used, 16-SAMSS-503 specifies a
continuous current rating of no less than 115% IFLA.
kVA Code/Locked-Rotor Amperes - The code letters marked on motor nameplates show
motor input kVA under locked-rotor (starting) conditions. The code letters for determining
motor branch-circuit short-circuit and ground fault protection are explained in NEC Article
430-52 and NEC Table 430-152.
Voltage - The protective device’s voltage rating is based on the system’s nominal voltage
rating and not on the motor’s nameplate voltage rating.
Horsepower - The motor’s nameplate horsepower rating is used to determine the kVA input
under locked-rotor conditions (see previous paragraph) and to determine the motor’s full-load
and locked-rotor amperes in accordance with NEC Tables 430-150 and 430-151.
Fault/Starting Currents
Under fault conditions, a motor supplies the same magnitude of current that it draws under
locked-rotor (starting) conditions (refer to Figure 29 of this Module). The protective device’s
interrupting rating must be greater than the symmetrical fault current available in the system,
and its trip rating must be greater than the asymmetrical starting current available.

Symmetrical Current - MCCBs and LVPCBs, like most other electrical equipment, are rated
based on their symmetrical interrupting capability (Isym). Combination motor controllers
(starters) that use magnetic-only MCCBs and MCPs are also rated (listed) on a symmetrical
current basis.
Asymmetrical Current - Although MCCBs and LVPCBs are rated symmetrically, they have
an implied asymmetrical rating (Iasy) as well. LVPCB asymmetrical ratings are 1.17 times
their symmetrical rating (Iasy = 1.17 Isym). MCCB asymmetrical ratings are 1.02, 1.09, and
1.17 times their symmetrical rating based on symmetrical interrupting ratings of 10 kA or less,
10.001 to
20 kA, and greater than 20 kA, respectively.
Types of Protective Devices
Molded Case Circuit Breakers (MCCBs) - The MCCB gets its name from the material
(plastic) and manufacturing process (molded) used to make the frame (case) of the breaker.
Figure 59 describes an MCCB. The MCCB serves both as the disconnect and the fault
protection for a motor.
Inverse-time MCCBs have a thermal-magnetic tripping action. The current path within the
breaker is through a bimetallic strip. A bi-metal consists of two strips of metal that are
bonded together. Each strip has a different thermal rate-of-heat expansion. As the current
passes through the bi-metal, the bi-metal strip heats up and bends. Greater current passing
through the bi-metal will generate more heat, resulting in faster bending of the strip. The bi-
metal continues to bend until it moves far enough to mechanically unlatch the breaker
mechanism, allowing the breaker to open. This thermal action is called an inverse
time/current characteristic (as the current increases, the time to trip is less).
For high fault currents, the thermal action is too slow to protect the downstream devices;
therefore, a magnetic trip action is used. The magnetic trip action functions by use of an
electromagnet that is in series with the load current. When a short circuit occurs, the fault
current passing through the circuit causes the electromagnet in the breaker to attract the
armature, initiating an unlatching action. This magnetic trip response is instantaneous. By
definition, instantaneous means “no intentional time delay”. The magnetic action is usually
adjustable within a range (5-10x) for large frame MCCBs, where x is the breakers’ ampere
trip (AT) rating.
Magnetic-only MCCBs are identical to the inverse-time MCCB except that the thermal trip
action is eliminated. Magnetic trip MCCBs are often used for motor fault protection because
the NEC also requires a separate device to provide overload protection for the motor.

Figure 59. Molded Case Circuit Breaker (MCCB)
Motor Circuit Protectors (MCPs) are identical to magnetic-only MCCBs except for the
ratings label. Magnetic-only MCCBs have an interrupting rating that is the same as the rating
for thermal-magnetic breakers (e.g., 14 kA, 25 kA, 65 kA). MCPs do not have a stand-alone
interrupting rating; they are rated as an assembly, which is called a combination motor starter,
consisting of overloads, a contactor, and a fault/disconnect device. The other minor
difference is that the MCP adjustments must be listed in amperes, whereas the magnetic-only
MCCB adjustments are typically listed in multiples of the trip (continuous current) rating.
Low Voltage Power Circuit Breakers (LVPCBs) are more rugged and more flexible and
generally have higher ratings than MCCBs. The designation “power circuit breaker” was
adopted after the introduction of the MCCB to differentiate between the two types. The term
unfortunately does not adequately describe these breakers, because all breakers in reality are
power breakers in that they make and break power circuits. The term power presumably was
chosen because these breakers can be used to handle large blocks of power up to 4000
amperes at 600 volts, three-phase, whereas the MCCBs originally could only handle loads up
to 600 amperes. Note: The National Electrical Manufacturers Association (NEMA) defines
the low voltage power circuit breaker as one for use on circuits rated 1000 vac and below, or
3000 vdc and below, but not including molded case breakers.

The LVPCB has an open-type heavy steel frame upon which the components are mounted,
making them more readily accessible. These breakers tend to be heavier, larger, and more
costly than MCCBs. Fixed LVPCBs are available for mounting in individual enclosures, but
generally the LVPCBs are of the drawout- type for mounting in metal-enclosed switchgear.
LVPCBs are closed by means of the two-step, stored-energy spring mechanism. Manual
operation is accomplished by first compressing a heavy spring by means of the operating
handle. With the closing spring compressed, the breaker can be closed at any time by pushing
the close button mounted on the breaker faceplate, which mechanically releases the spring.
Electrical operation uses an electric gear motor to compress the spring. The breaker is then
closed by electrically activating a small closing solenoid, which releases the closing spring.
The breakers are opened manually by pressing the separate trip button mounted on the
breaker faceplate, which mechanically unlatches the breaker, allowing the opening springs to
rapidly force the main contacts apart. The breakers are opened electrically by energizing a
shunt trip coil from a remote pushbutton, which then similarly unlatches the breaker contacts.
Solid-state type trip units have universally replaced the mechanical dual-magnetic trip units
that were the standard for many years. The solid-state trip units consist of three components:
current sensors, the solid-state unit itself, and a separate shunt-trip mechanism.
Ratings
Molded Case Circuit Breakers (MCCBs) are rated as follows:
• Frame sizes (AF) of 100 A, 225 A, 400 A, ..., 6000 A.
• Trip ratings (AT) of 15 A, 20 A, 25 A, ..., 6000 A; NEC Article 240-6 lists all
37 standard AT ratings.
• Amperes interrupting capability (AIC) ratings of 10 kA, 14 kA, 18 kA, ..., 100
kA; no standard exists for AIC typical ratings.
• Voltage ratings of 120 V, 240 V, 277 V, 480 V, and 600 V.

The interrupting rating or short circuit rating at a 400C ambient temperature is commonly
expressed in root mean square (RMS) symmetrical amperes. The interrupting capability of
the breaker may vary with the applied voltage. For example, a breaker applied at 480 volts
could have an interrupting rating of 25,000 amps at 480 volts, but the same breaker applied at
240 volts may have an increased interrupting rating of 65,000 amps. All MCCBs operate
instantaneously at currents well below their interrupting rating. Non-adjustable MCCBs will
usually operate instantaneously at current values approximately five times (5x) their trip
rating. Low voltage breaker contacts separate and interrupt the fault current during the first
cycle of short circuit current. Because of this fast operation, the momentary and interrupting
duties are considered to be the same. Therefore, all fault contribution from generators,
motors, and the dc components of the fault waveform must be considered. Magnetic-only
MCCB ratings are identical to the thermal-magnetic MCCB. Figure 60 lists the typical ratings
for both thermal-magnetic and magnetic-only MCCBs.
Motor Circuit Protectors (MCPs) are recognized components in UL 480 listed control
assemblies, which includes contactors and overload relays. MCPs are sized to correspond
with NEMA starter sizes (0, 1, 2, 3, 4, 5, 6), and, as mentioned previously, their adjustments
must be labeled in amperes. MCPs are tested in combination with a specific contactor and
overload relays to establish their maximum symmetrical interrupting capability. Typical
ratings are 65 kA at 480 V, increasing to 200 kA when combined with fuse limiters. MCPs
are voltage-rated up to 600 V, with typical continuous current ratings ranging from 3 to 600
A. Figure 61 lists the ratings and adjustments of a typical family of MCPs.

Line Frame Rated Interrupting Current Rating (AIC)

No. Size Continuous (amps)
(amps) Current 240 Volts 480 Volts 600 Volts
(AF) (amps) Sym Asym Sym Asym Sym Asym
(AT)
1 100 10-100 18,000 20,000 14,000 15,000 14,000 15,000
2 100 10-100 65,000 75,000 25,000 30,000 18,000 20,000
3 100 10-100 100,000 -- 100,000 -- 100,000 --
4 225 125-200 22,000 25,000 18,000 20,000 14,000 15,000
5 225 70-225 25,000 30,000 22,000 25,000 22,000 25,000
6 225 70-225 65,000 75,000 35,000 40,000 25,000 30,000
7 225 70-225 100,000 -- 100,000 -- 100,000 --
8 225 70-225 35,000 40,000 25,000 30,000 22,000 25,000
9 400 200-400 65,000 75,000 35,000 40,000 25,000 30,000
10 400 200-400 100,000 -- 100,000 -- 100,000 --
11 400 200-400 42,000 50,000 30,000 35,000 22,000 25,000
12 600 300-600 100,000 -- 100,000 -- 100,000 --
13 800 300-800 42,000 50,000 30,000 35,000 22,000 25,000
14 800 300-800 65,000 75,000 35,000 40,000 25,000 30,000
15 800 600-800 100,000 -- 100,000 -- 100,000 --
16 1000 600-1000 42,000 50,000 30,000 35,000 22,000 25,000
17 1200 700-1200 42,000 50,000 30,000 35,000 22,000 25,000
Figure 60. Typical MCCB Ratings

Figure 61. Typical MCP Ratings and Settings
Low Voltage Power Circuit Breakers (LVPCBs) are designed and marked with the
maximum voltage at which they can be applied. They can be used on any system where the
voltage is lower than the breaker rating. The applied voltage will effect the interrupting rating
of the breaker. Standard maximum voltage ratings for LVPCBs are 635 volts, 508 volts, and
254 volts. LVPCBs are usually suitable for both 50 and 60 Hz.
The rated continuous current of an LVPCB is the designated limit of RMS current, at rated
frequency, that the LVPCB is required to carry continuously, without exceeding the
temperature limitations based on a 400C ambient temperature. The temperature limit on
which the rating of LVPCBs are based is determined by the characteristics of the insulating
materials and the metals that are used in the current carrying components and springs.
Standard frame size ratings for low voltage power circuit breakers are 800, 1600, 2000, 3200,
and 4000 amperes. Some manufacturers may have additional frame sizes. LVPCBs have
either an electromechanical trip or a solid-state trip that is adjustable or interchangeable from
a minimum rating up to the ampere rating of the frame.

The interrupting rating of an LVPCB is the symmetrical current rating of the circuit breaker.
The asymmetrical interrupting rating is implied, and it is based on an X/R ratio of 6.6 for
unfused breakers and an X/R ratio of 4.9 for fused breakers. An X/R ratio of 6.6 corresponds
to an A.F. (Ma) of 1.17. Most low voltage systems have an X/R ratio of less than 6.6.
Therefore, if an asymmetrical interrupting rating is not listed by the manufacturer, assume that
the asymmetrical rating is 1.17 times the symmetrical rating.
The short-time current rating of an LVPCB specifies the maximum capability of the circuit
breaker to withstand the effects of short circuit current flow for a stated time period, which is
typically 30 cycles or less. The short-time delay on the breaker’s trip units corresponds to the
breaker’s short-time current rating. This time delay provides time for downstream protective
devices closer to the fault to operate and isolate the circuit. The short-time current rating of a
modern day LVPCB without an instantaneous trip characteristic is usually equal to the
breaker’s short circuit interrupting rating. By comparison, MCCBs usually do not have a
short-time rating.
Figure 62 lists the frame and sensor ratings of a typical LVPCB, and Figure 63 lists the short-
time and interrupting ratings of a typical LVPCB.
Frame Size (amperes) Available Sensor Ratings

(amperes)
800 50, 100, 150, 200, 300, 400, 600, 800
1600 100, 150, 200, 300, 400, 600, 800, 1200, 1600
2000 100, 150, 200, 300, 400, 600, 800, 1200, 1600, 2000
3200 2400, 3200
4000 4000
Figure 62. LVPCB Frame and Sensor Ratings
Frame Interrupting Ratings (RMS Symmetrical Amperes)

Size Short-TimeRatings-30cycles
(amperes) With Instantaneous Trip (WithShort-Delay)
208-240V 480 V 600 V 208-240V 480 V 600 V
800 42,000 30,000 30,000 30,000 30,000 30,000
1600 65,000 50,000 42,000 50,000 50,000 42,000
2000 65,000 65,000 50,000 65,000 65,000 50,000
3200 85,000 65,000 65,000 65,000 65,000 65,000
4000 130,000 85,000 85,000 85,000 85,000 85,000
Figure 63. LVPCB Short-Time and Interrupting Ratings

Combination Motor Starters - When the disconnect and/or branch circuit fault protective
device and the controller (starter) are at the same location, they can be combined into a single
enclosure that is called a combination motor starter. The combination motor starter is a much
more compact unit that saves both space and installation costs, and that increases safety,
because the cover of the starter is interlocked with the protective/disconnect to prevent
opening unless the disconnecting means is in the “off” position.
The rating of combination motor starters is based on maximum horsepower, voltage, NEMA
starter size, continuous amperes, and interrupting amperes. The standard interrupting rating
of MCPs and magnetic-only breakers is 65 kA. Optional units are available on the market
that increase the interrupting capacity to 100 kA by adding current limiters to the breaker.
Figure 64 lists the ratings of typical combination motor starters up to a maximum rating of
100 hp. Note: Higher rated (greater than 100 hp) combination starters are available, but
they are not listed in Figure 64 because SAES-P-114 limits their application to low voltage
motors that are rated 100 hp and below.
NEC Maximum Settings
NEC Table 430-152 specifies maximum settings to provide motor branch-circuit short circuit
and ground fault protection.
Inverse-Time MCCBs - NEC Table 430-152 specifies a setting not to exceed 250% IFLA for
inverse time MCCBs. Because an MCCB will trip on its instantaneous function at 5 times its
trip rating, the NEC in effect limits the trip rating under motor starting conditions to 12.5
(5 x 2.5). If this setting nuisance trips the motor under starting conditions, NEC Article 430-
52 permits increasing the rating to 400%, where IFLA is 100 amperes or less, and 300% where
IFLA is greater than 100 amperes.
Magnetic-Only MCCBs and MCPs - NEC Table 430-152 specifies a maximum setting of
700% IFLA and an absolute maximum of 1300% IFLA if, under motor starting conditions, the
protective device nuisance trips.
LVPCBs - The NEC does not explicitly specify LVPCB settings for motor protection. For
NEC purposes, if the LVPCB is used as an inverse time breaker, it must comply to the same
rules as an inverse time MCCB.

Max Motor NEMA Continuous Breaker

hp Volts Size Amperes Amperes
7.5 200 1 27 30
7.5 230
10 460
10 575
10 200 2 45 50
15 230
25 460
25 575
25 200 3 90 100
30 230
50 460
50 575
40 200 4 135 150
50 230
100 460
100 575
75 200 5 270 400
100 230
Notes: a. For motor horsepower ratings less than 7.5 hp, NEMA Size 0 starters are
available.
b. Combination starter interrupting ratings are 65 kA; 100 kA ratings are
also available if current limiter attachments are installed.
Figure 64. Typical Combination Motor Starter Ratings

Protective Device T/C Characteristics
Molded Case Circuit Breakers (MCCBs) - Saudi Aramco (SAES-P-114) permits the
following three types of molded case circuit breakers (MCCB) to be used for motor phase
fault protection.
• inverse-time (thermal-magnetic)
• magnetic only
• motor circuit protectors (MCPs)
Inverse-time (thermal-magnetic) MCCBs are permitted by SAES-P-114 for low voltage

motors that are rated 1.0 hp or less. The NEC also permits their use as long as their
continuous current rating does not exceed 250 percent of the motor’s full-load amperes (IFLA),
as listed in NEC Table 430-150. Although most codes and standards permit use of inverse-
time MCCBs, they are typically not used because of nuisance tripping caused by high motor
starting inrush currents (typically 4-6 IFLA). Figure 65 shows the T/C characteristics of an
MCCB protecting a 1.0 hp motor. Note: Although Figure 42 shows, and the NEC permits,
the MCCB providing both overload and short circuit protection, it is not recommended
practice. Magnetic-only MCCBs are also permitted by SAES-P-114 for low voltage motors
that are rated 1.0 to 100 hp. The NEC also permits their use as long as their rating (setting)
does not exceed 700 percent of the motor’s full-load amperes (IFLA), as listed in NEC Table
430-150, and if the MCCB is part of a listed combination controller. Figure 66 shows the T/C
characteristics of a magnetic only MCCB protecting a 100 hp motor.
Motor Circuit Protectors (MCPs), like magnetic-only MCCBs, are permitted by SAES-P-
114 for low voltage motors rated 1.0 to 100 hp. NEC Article 430-52 also permits their use as
long as they are part of a listed combination controller and they are set at not more than 1300
percent of the motor’s full load amperes (IFLA), as listed in NEC Table 430-150. Figure 67
shows the T/C characteristics of an MCP protecting a 100 hp motor.
Low Voltage Power Circuit Breakers (LVPCBs) - SAES-P-114 requires use of LVPCBs
for fault protection (phase and ground) for all low voltage motors rated above 100 hp.
Modern solid-state trip (SST) units are typically available with the following trip functions:
• Long Time/Instantaneous (LI)

• Long Time/Short Time (LS) with or without I2t
• Long Time/Short Time/Instantaneous (LSI)
• Long Time/Instantaneous/Ground (LIG) with or without I2t
• Long Time/Short Time/Ground (LSG)
• Long Time/Short Time/Instantaneous/Ground (LSIG)

Figure 68 shows the T/C characteristics of an LVPCB, with a solid-state trip unit, protecting a
200 hp low voltage motor.
Figure 65. Thermal-Magnetic MCCB Fault Protection

Figure 66. Magnetic-Only MCCB Fault Protection

Figure 67. MCP Fault Protection

Figure 68. LVPCB Motor Protection

SIZING MOTOR CIRCUIT CONDUCTORS
Note: Work Aid 2 has been developed to teach the Participant procedures to size motor
circuit conductors.
Introduction
Branch circuit and feeder conductor sizing for ac induction motors requires special
consideration because motors have unique starting and running characteristics. The branch
circuit and feeder conductors must be rated to carry the maximum load current that the motor
is permitted to carry on a continuous basis. In addition, the motor conductors must be
checked for voltage drop limits and short circuit withstand capabilities. Note: The material
presented in this Information Sheet will limit the discussion to continuous rated low voltage
ac induction motors. Special purpose motors, varying duty cycle motors, etc., are considered
beyond the scope of this Module (Information Sheet).
Motor Circuit Diagrams
Motor Branch Circuits
The National Electric Code (NEC) defines a motor branch circuit as a single motor’s circuit,
consisting of all conductors and electrical equipment between the final overcurrent device, for
example an MCP, protecting the motor and the motor itself. Figure 69a illustrates the typical
components of a motor branch circuit in three-line diagram form, and Figure 69b shows the
corresponding one-line diagram. The typical components of a motor branch circuit are the
following:
• Branch circuit, short circuit, and ground fault protective device (NEC Article
430-52)
• Branch circuit conductors (NEC Article 430-22)
• Motor controller with overload protection (NEC Articles 430-32 and 430-83)
• Motor disconnect device (NEC Article 430-109)
Note: As discussed in the previous Information Sheets, one device is permitted by the NEC to
serve more than one function. For example, an MCP is both the fault protective device and
the disconnect device.

Figure 69. Motor Branch Circuit

Motor Feeder Circuits
The NEC defines a motor feeder circuit as the circuit for two or more motors, or a single
motor and other loads, and that consists of all conductors between the service equipment and
the final branch circuit overcurrent protective device. Figure 70 illustrates a typical motor
feeder circuit one-line diagram.
Figure 70. Motor Feeder Circuit One-Line Diagram

Motor Nameplate Data
NEC Article 430-F states a motor nameplate must be marked with the following information:
• volts, full-load amperes, service factor, horsepower

• temperature factors, time (duty), locked-rotor codes
• maker’s name, frequency, number of phases, speed
Figure 71 illustrates an example nameplate that contains the NEC’s minimum required
nameplate information. Saudi Aramco standards also require the nameplate to contain
additional information pertaining to insulation class, winding temperature rise, type of
bearings, rotor Wk2, and types of enclosure.
Figure 71. Typical AC Induction Motor Nameplate

Voltage
Per NEMA MG-1, the voltage marked on the motor nameplate is the rated motor terminal
voltage. The nominal three-phase system voltages that match the rated three-phase voltages
are listed in Figure 72.
Figure 72. AC Motor Voltages
Full-Load Amperes
The full-load amperes marked on the motor nameplate are based on the rated voltage,
horsepower, and frequency. Overload protection, as specified by NEC Article 430-32, is
based on the marked full-load amperes rating of the motor.
Service Factor (S.F.)
When the voltage and frequency are maintained as per the nameplate markings, the motor
may be overloaded up to the hp obtained by multiplying the rated hp times the service factor
(S.F.) shown on the nameplate. When the motor is operated at the higher service factor,
efficiency, power factor, and speed may be different than at rated load, but locked-rotor
torque and current, and breakdown torque remain unchanged. For example, a 100 hp, 1.15
S.F. motor may be safely loaded to 115 hp. Note: Saudi Aramco only specifies 1.0 S.F.
motors.

Horsepower
Horsepower is the rated output mechanical power that may be applied to the motor shaft. IEC
motors are rated on output kW versus output hp, where 1 hp equals 0.746 kW. For example,
a NEMA MG-1 rated 100 hp motor is equivalent to a nominal 75 kW (74.5 kW actual) IEC-
rated motor.
Temperature Factors
The temperature rise or the insulation class and ambient temperature must be marked on the
motor (Figure 73). Saudi Aramco motor specifications (17-SAMSS-502 and 503) require
Class F insulation. However, for fractional-rated horsepower motors, SAES-P-113 permits,
as a minimum, Class B insulation.
Figure 73. NEMA Temperature Ratings
Temperature Rise/Insulation Class/Ambient Temperature - The temperature rise shown in Figure 73

is based on motor operation at altitudes of 1000 meters (3300 ft) or less, ambient temperatures
of 400C, and rated horsepower for 1.0 S.F. motors or 1.15 times rated horsepower of 1.15 S.F.
motors. The insulation class as shown above (Figure 73) is based on a 400C ambient, but if
the motor is operated at higher ambient, the motor temperature rise must be calculated in
accordance with NEMA MG 1-12.43.

Time (Duty)
Per NEMA MG 1-10.36, the time ratings for motors are 5, 15, 30, and 60 minutes, and
continuous duty. Note: Saudi Aramco standards only specify continuous duty motors.
Locked-Rotor Codes
Both NEMA MG 1-10.37 and the NEC require that the locked-rotor indicating code letters be
marked on the motor nameplate. The letter designations are based on full voltage and rated
frequency (Figure 74).
Figure 74. Locked-Rotor kVA Codes
Miscellaneous Data
Maker’s Name - The NEC requires the motor manufacturer’s name to be marked on the
nameplate. Most manufacturers also include additional markings such as serial numbers,
model numbers, bearing numbers, etc.
Frequency and Number of Phases - The motor frequency (50 or 60 Hz), as well as the
number of phases (1 or 3), are required markings on the motor nameplate. Virtually all other
ratings are based on loadings at rated frequency. All ac motors are required by NEMA MG 1-
12.44 to operate successfully under running conditions at rated load and voltage, and at plus
or minus
5 percent frequency.
Speed - NEMA MG 1-10 lists the synchronous speed of motors (Nrpm = 120 f/p), whereas the
nameplate speed for induction motors includes slip (rotor speed).

Motor Branch Circuit Conductor Selection Factors
Note: Work Aid 2D has been developed to teach the Participant procedures to select motor
branch circuit conductors.
NEC Tables for Motor Full-Load Amperes
NEC Article 430-6(a) requires that the ampacity ratings of motor branch circuit conductors be
based on the values listed in NEC Tables 430-147 to 430-150 (including the notes to the
tables), instead of being based on the actual continuous current rating marking on the motor
nameplate, whereas the motor overload protective device rating is based on actual motor
nameplate full-load amperes.
NEC Article 430-22 requires that the branch circuit conductors supplying a single motor shall
have an ampacity of not less than 125 percent of the motor full-load amperes, as listed in NEC
Tables 430-147 to 430-150.
Example A: Using Work Aid 2D procedures, what is the minimum size branch circuit
conductor permitted by the NEC supplying a 30 hp, 3-phase, 460 volt motor?
Assume that type THWN copper conductors are being used for the branch
circuit.
Answer: Per NEC Table 430-150, the ampacity of a 30 hp, 3-phase, 460 volt motor is
40 amperes. The minimum conductor ampacity is 50 A (1.25 x 40). Per NEC
Table 310-16, the minimum size type THWN (750C) copper conductor is
No. 8 AWG, which has a rated ampacity of 50 A.
Short Circuit Ratings
A cable must be protected from overheating due to excessive short circuit (fault) currents.
The fault point may be on a section of the protected cable or on any other part of the electric
system. During a phase fault, the I2R losses in the phase conductor elevate first the
temperature of the conductor, followed by the insulation material, protective jacket, raceway,
and surroundings.
Because the short circuit current should be interrupted either instantaneously or in a very short
time by the protective device, the amount of heat transferred from the metallic conductors
outward to the insulation and other materials is very small. Therefore, the heat from I2R
losses is almost entirely in the conductors, and for practical purposes, it is assumed that 100%
of the I2R losses is consumed to elevate the conductor temperature. During the period that the
short circuit current is flowing, the conductor temperature should not be permitted to rise to
the point where it may damage the insulation.

Calculating the short circuit ratings of conductors was discussed in detail in Module 103.01,
and in particular, Work Aid 1G of the same Module. As a review, the basic procedure is to
compare the short circuit duration (t) to the protective device’s clearing time. If t is less than
the clearing time, increase the conductor size to the next standard available size, and repeat
the process until t is greater than the protective device’s clearing time.
Example B: Using Work Aid 2D procedures, how quickly must a protective device (i.e., an
MCP) clear a 5 kA asymmetrical fault for the No. 8 AWG copper conductor
that was selected in Example A?
Answer: Using Figure 88 of Work Aid 2D, a No. 8 AWG copper conductor can
withstand a 5 kA fault for approximately 4cycles(0.0667sec).
Voltage Drop
Designers of power systems must have practical knowledge of voltage drop calculations, not
only to meet required codes and standards, but to ensure that the required voltage of a
particular piece of equipment, for example, a motor is kept within manufacturer’s specified
tolerances to prevent damage to the equipment.
The voltage drop on the motor branch circuit depends on the motor full-load amperes and the
type and length of the branch circuit conductors.
As was the case with determining the short circuit ratings of conductors, calculating the
voltage drop was also discussed in detail, in Module 103.01, and in particular, Work Aid 1H
of the same Module. As a review, the basic procedure is to calculate the voltage drop. If the
voltage drop exceeds the SAES-P-100 specified limit of 3 percent, increase the conductor size
to the next standard available size, and repeat the process until the voltage drop is less than
the 3 percent maximum limit.
Example C: Per NEC Table 9, the ac impedance of the No. 8 AWG copper conductor that
was specified in Example A is (0.780 + j 0.065) Ω/1000 ft. Using Work Aid
2D, what is the voltage drop if the branch circuit length is 50 feet? Assume
that the motor power factor is 80%.
Answer: 1. IFLA = 40 A, p.f. = 0.80, sin θ = sin (cos-1 .80) = 0.60
2. Z = (R + jX) Ω/1000 ft x no. of ft

= [(0.780 + j 0.065)/1000] (50)
= 0.039 + j 0.00325

3. VD(L-N) = I (R cos θ + X sin θ)

= (40) [(0.039)(0.80) + (0.00325)(0.60)]
= 1.326 volts
4. VD(3φ) = 3 VD(L-N)
= ( 3)(1.326) ≈ 2.3 volts
5. VD% = 100(2.3/480) = 0.5%
Conduit Sizes
The number of conductors permitted in a conduit is restricted by the NEC. The total cross-
sectional area of the conductors, which includes the insulation, must not exceed a specified
percentage of the wireway or conduit cross-sectional area. The NEC refers to this restriction
as “percentage fill”. Exceeding the percentage fill can cause physical damage to the
conductors as they are being installed (pulled) through the raceway. Additionally, the heat
buildup in the raceway could be excessive, resulting in damage to the insulation. The conduit
must be sized to carry the phase branch circuit conductors and the equipment grounding
conductors (EGC). If the overcurrent device protecting the branch circuit conductor is a
thermal-magnetic MCCB or an LVPCB, the equipment grounding conductors are sized based
on the continuous current rating of the MCCB or LVPCB. If the protective device is an
instantaneous only trip MCCB or an MCP, the equipment grounding conductors are sized
based on the rating of the overload protective device (see NEC Article 250-95).
Example D: Using Work Aid 2D procedures, what is the minimum trade size conduit
permitted by the NEC to enclose the No. 8 AWG THWN copper conductors
that are supplying power to the 30 hp motor that was described in Example A?
Answer: 1. Assuming an O/L protective device maximum setting of 115% for 1.0
S.F. motors, the minimum ampacity is 46 A (1.15 x 40). Therefore, per
NEC Table 250-95, select a No. 10 AWG THWN equipment grounding
conductor.
2. Per NEC Table 3B, 4 No. 8 AWG conductors will fit in a 3/4-inch trade
size conduit.

Motor Feeder Circuit Conductor Selection Factors
Note: Work Aid 2F has been developed to teach the Participant procedures to select motor
feeder circuit conductors.
Full-Load Amperes (All Motors)
NEC Article 430-24 specifies that conductors supplying several motors, or a motor(s) and
other load(s), shall have an ampacity rating at least equal to the sum of the full-load current
rating of all the motors, plus 25 percent of the highest rated motor in the group, plus the
ampere rating of other loads that are computed in accordance with Article 220 and other
applicable sections. Note: Assume that only motors will be connected to the feeder circuit.
Example E: Referring to Figure 70 and using Work Aid 2F procedures, what is the
minimum size feeder conductor permitted by the NEC? Assume type THWN-2
(900C) copper conductors.
Answer: 1. I = 14 + 21 + 27 + 34 + (.25 x 34) = 104.5 A
2. Per NEC Table 310-16, a No. 3 AWG will safely carry 110 A.
However, select a No. 2 AWG because it is more commercially
available.
Short Circuit Ratings
Determining the short circuit rating of a motor feeder conductor is identical to determining the
short rating of a motor branch circuit conductor, or any non-motor load conductor. The
protective device must operate faster than the duration time (t) that the conductor can
withstand for a given asymmetrical current.
Example D: Using Work Aid 2F procedures, how quickly must a protective device (i.e., an
LVPCB) clear a 10 kA asymmetrical fault for the No. 2 AWG copper
conductor that was selected in Example E?
Answer: Using Figure 88 of Work Aid 2D, a No. 2 AWG copper conductor can
withstand a 10 kA fault for approximately 30 cycles (0.500 sec).

Voltage Drop
Calculating the voltage drop for motor feeder conductors is not any different than calculating
the voltage drop for any other conductor. SAES-P-100 does however, limit the drop to 3
percent if the motor control equipment is located remotely from the supply switchgear
(source) and to a 1 percent voltage drop limit if the supply switchgear is located in the same
room.
Example G: Per NEC Table 9, the ac impedance of the No. 2 AWG copper conductor
specified in Example A is (0.020 + j .057) Ω/1000 ft. Using Work Aid 2F,
what is the voltage drop if the feeder circuit length is 150 feet? Assume that
the motor feeder circuit power factor is 85%.
Answer: 1. IFLA = 96 A, p.f. = 0.85, sin θ = sin (cos-1 .85) = 0.527
2. Z = [(R + jX) Ω/1000 ft] x no. of ft

= [(0.020 + j 0.057)/1000] (150)
= 0.03 + j 0.0086 Ω
3. VD(L-N) = I (R cos θ + X sin θ)

= (96)[0.03)(0.85) + (0.0086)(0.527) = 2.883 volts
4. VD(3φ) = 3 VD(L-N) =( 3)(2.883) ≈ 4.99 volts
5. VD% = 100(4.99/480) = 1.04%
Conduit Sizes
As with the motor branch circuit conductor conduit sizes, the feeder conductor conduit must
be sized to carry the three phase conductors and the equipment grounding conductor (EGC).
The EGC is sized, per NEC Article 250-95, based on the ampere trip rating of the feeder
protective device, which is sized per NEC Article 430-62. NEC Article 430-62 specifies that
a feeder supplying a specific fixed motor load(s), and consisting of conductor sizes based on
Section 430-24, shall be provided with a protective device having a rating or setting not
greater than the largest rating or setting of the branch circuit short circuit and ground fault
protective device for any motor of the group, plus the sum of the full-load amperes of the
other motors of the group. The feeder protective is sized based on the assumption that the
largest motor is started at an instant in time when all the other motors are already running.

Example H: Referring to Figure 70 and using Work Aid 2F procedures, what is the
minimum trade size conduit permitted by the NEC to enclose the No. 2 AWG
copper feeder conductors that are supplying power to the group of motors?
Assume that the MCP protecting the 25 hp motor is set at 250 A.
Answer: 1. LVPCB setting shall not exceed 312 A (250 + 14 + 21 + 27).

Therefore, the LVPCB setting should be set at 300 A. Per NEC Table
250-95, select a No. 4 AWG THWN-2 EGC.
2. Per NEC Table 3B, 4 No. 2 AWG THWN-2 conductors will fit in a
1 1/4-inch trade size conduit.

WORK AID 1: RESOURCES USED TO SELECT A LOW VOLTAGE

COMBINATION AC INDUCTION MOTOR STARTER
Work Aid 1A: SAES-P-114
1. Para 6.2.1 Induction Motors, 600 V or Less, 1.0 HP or Less:
Controller Types and Protection: a) Molded case circuit breaker with

three-pole thermal-magnetic trip unit or, b) Combination controller with
contactor, three-pole thermal-overload device, and three-pole magnetic-
trip (or thermal-magnetic trip) molded case circuit breaker.
2. Para 6.2.2 Induction Motors, 600 V or Less, Greater than 1 to 100 HP:
Controller types and Protection: Combination controller with contactor,

three-pole thermal-overload device, and three-pole magnetic-trip (or
magnetic trip molded case circuit breaker (or motor circuit protector).
Additional Devices:
50GS Instantaneous, ground fault relay, adjustable pickup, connected to

window CT or sensor. Required for motors 30 hp or greater.
37 Undercurrent relay for submersible pump motors only.
3. Para 6.2.3 Induction Motors, 600 V or Less, Greater than 100 HP:
Controller types: LV power circuit breaker, drawout-type, electrically-

operated with shunt-trip device. Minimum continuous current rating of
breaker shall be 115% of motor full load current.

4. Figure 79 lists the relays and their functions that are used for low voltage protection of
motors that are rated greater than 100 hp.
DEVICE RELAY FUNCTION TRIPS
27 (Note 1) Undervoltage Breaker
37 (Note 2) Undercurrent Breaker
49 Thermal Overload Breaker

(Three phases)
50/51 SST Solid State Trip Breaker

Phase & Ground
50 GS Ground Sensor Breaker
Notes:
1. Provide individual relays for each motor or a common relay on the motor bus.
2. Only required for submersible pump motors.
Figure 79. SAES-P-114 Relay Selection and Functions

Work Aid 1B: IEEE Standard C37.96-1988, IEEE Guide for AC Motor Protection
As an aid to assist motor users in considering and planning adequate protection for induction
motors, the IEEE Power Engineering Society has prepared a summary of protection circuits
used in general applications. The circuits, prepared as a guide for the adequate selection of
motor protection and published in IEEE Standard C37.96, recommend the same policies and
protection methods as discussed in this Information Sheet. However, the information is
categorized and presented in a slightly different format.
For the benefit of the Participants, and to show the approach taken by IEEE Standard C37.96,
the suggested protection circuits and their accompanying information tables are included in
this Work Aid (Figures 80 through 85).
1. Low Voltage Motor Controllers:
Figure 80. One-Line Diagram For Low Voltage Motor Controller

Ratings: Range of Ratings

Continuous Amperes 9 - 2250
Utilization voltage 200 - 575
Horsepower 1.5 - 1600
Starter size 00 - 9
NEMA
Types of Protection: Quantity Designation
Overload
Overload Relay elements 3 OL
Short Circuit
Circuit-breaker current trip elements 3 CB
Fuses
Undervoltage:
Inherent with integral control supply and three-wire control
circuit
Ground fault (when specified) 1 GP
Ground relay with toroidal current transformer
Figure 81. Device Table for Low Voltage Motor Controller
2. LVPCB Starter with Series Trip Device:
Figure 82. One-Line Diagram For LVPCB Starter with Series Trip

Ratings: Range of Ratings

Nominal voltage 240 - 600
Symmetrical amperes interrupting capacity at maximum rated voltage 14,000 - 130,000
Standard Device NEMA

Types of Stator Protection Device (all direct acting): Quantity Function Number Designation
Overload
Static trip devices 3 51
Short Circuit
Fuses 3 FU
Static trip devices 3 50
Undervoltage
Time-delay undervoltage relay 1 27
Ground fault
Overcurrent relay with toroidal current transformer 1 50G (or 51G)
Figure 83. Device Table for LVPCB with Series Trip
3. LVPCB with Protective Relays and Electrical Tripping:
Figure 84. One-Line Diagram For LVPCB with Protective Relays and Electrical
Tripping


Ratings Range of Ratings

Nominal voltage 240 - 600
Symmetrical amperes interrupting capacity at maximum rated voltage 14,000 - 85,000
Standard Device NEMA

Types of Stator Protection Device Quantity Function Designation
Overload Number
Static trip devices 3
Thermal-overcurrent relay 3 51
Time-overcurrent relay 3 49
51
Short Circuit
Fuses 3 FU
Static trip devices 3
Instantaneous Overcurrent relay 2 or 3 50
50
Ground fault
Time-overcurrent relay, residual connection 1
Time-overcurrent relay with toroidal CT 1 51N GP
Undervoltage
Direct-acting time-delay undervoltage relay 1
27
Note: See Figure 84.
Figure 85. Device Table for LVPCB with Protective Relays

and Electrical Tripping

Work Aid 1C: 16-SAMSS-503
1. Section 5.1.2 requires that overload relays be Class 20 unless otherwise specified. For
example, if motor acceleration time is known to exceed 20 seconds, Class 30 should
be specified and selected.
2. Section 5.1.3 permits the O/L relay to be thermally actuated, bimetalic (block-type)
style, or solid-state style. For purposes of this Module, use bimetallic block-type style.
3. Section 5.1.3 requires that overload relays be of the manual-reset type unless
otherwise specified and that they have a field-adjustable trip setting with a minimum
range of 85% to 100% of the heater element rating. Note: Type B O/L relays do not
have field adjustable trip settings.
4. Section 5.1.3 requires that thermally actuated, bimetallic overload relays be

temperature compensating from 00C to 750C.
5. Section 5.1.3 requires that thermally actuated overload relays be block-type with
bimetallic type heater elements. By definition, a block-type relay is a single three-pole
block overload relay.
6. Section 5.4.4 requires that only combination controllers be used for motors that are
rated 600 V and below, and 1 to 100 horsepower.
7. Section 5.4.4 requires that motor controllers be 600 V, three-pole, general purpose,
NEMA Class A, air-magnetic-type motor controllers that are rated in horsepower and
that conform to the requirements of NEMA ICS 2-321.

Work Aid 1D: 1993 National Electric Code (NEC) Handbook Article 430
For the content of Work Aid 1D, refer to Handout 1.

Work Aid 1E: Manufacturer’s Literature, Westinghouse Catalog 25-000
For the content of Work Aid 1E, refer to Handout 3.

Work Aid 1F: Manufacturer’s Literature, Westinghouse SA-11647, Low Voltage

Metal Enclosed Switchgear - Type DS
For the content of Work Aid 1F, refer to Handout 4.

Work Aid 1G: Applicable Procedures for Selecting an O/L Relay
1. Collect the following information from the motor nameplate:
• full-load amperes nameplate (FLA) -

• service factor (S.F.) -
Note: Saudi Aramco specifies only 1.0 S.F. motors.
2. Determine the operating ambient temperatures for the motor environmentand for the
controller environment.
• Motor ambient (0C) -

• Controller ambient 0C -
3. Using NEC Article 430-32 (Work Aid 1D, Handout 1), determine the trip current, or
rating, for the overload relay to be selected. NEC Article 430-32(a) states that the
maximum trip current, or rating of an overload relay, when protecting a continuous-
duty motor, is determined in accordance with Figure 86.
Motor Parameter Percent of Motor Nameplate

Full-Load Amperes (FLA)
* Motors marked with 125%

SF ² 1.15
* Motors marked with 125%

temperature rise ² 40oC
All other motors 115%
* Note: If the nameplate is not marked with the service factor (S.F.) or
temperature rise, the stated condition does not apply to the selection
of the trip current, or rating, of the overload relay.
Figure 86. NEC Table 430-32

4. Determine the style of overload relay to be selected. Select bimetallic style.
5. Determine the class of overload relay to be selected: Select Class 20.
6. Determine the type of overload relay to be selected: Type A or Type B. Select Type
A.
7. Determine if the overload relay to be selected is to be compensated or non-

compensated for ambient temperature. Select ambient compensated.
8. Using the overload relay selection parameters determined in Steps 1 through 7, select
an overload relay from Westinghouse Catalog 25-000, pages 469 - 472 (Work Aid 1E,
Handout 3). If current is to be supplied to the O/L relay through a current transformer
(CT), the selection parameter of motor full-load amperes (FLA) must be divided by the
ratio of the CT before it is used to select the O/L relay. For example, if the O/L relay
is intended to monitor the motor current through a 300/5 (or 60/1) CT, the parameter
used to select the O/L relay must be (FLA)/60.
9. To complete the selection of the O/L relay, select the appropriate heater elements for
the relay. Select the heater elements from Westinghouse Catalog 25-000, page 473
(Work Aid 1E, Handout 3), by using the following information:
• NEMA size contactor used for starter

• full-load nameplate amperes (FLA) (from Step 1)
• service factor (S.F.) (from Step 1)
• ultimate trip current for overload relay (from Step 3)
• temperature compensation requirement (from Step 7)
• overload relay type (from Step 6)
10. 16-SAMSS-503 (Work Aid 1C) and SAES-P-114 (Work Aid 1A) require that only
combination controller’s be used for motors that are rated 600 V and below, and 1 to
100 horsepower. As a result, O/L relays are supplied by the manufacturer as an
integral component of the combination controller. These selection procedures provide
for verifying the selection of O/L relays that are provided with combination
controllers.

Work Aid 1H: Applicable Procedures for Selecting a Contactor
1. Collect the following information from the motor nameplate:
• motor horsepower (hp) -

• motor voltage (VM) -
• number of phases (1 or 3) -
2. Determine the type of contactor to be selected. Select an air-magnetic contactor.
3. Determine the minimum size contactor to select based on the motor’s horsepower and
voltage ratings. Select ____ hp or larger.
4. Determine whether a reversing or non-reversing contactor is to be selected. Note:

This selection parameter is determined from the operating conditions for the starter.
5. Determine the coil voltage rating for the contactor to be selected. The coil voltage
rating must be equal to the control circuit voltage rating. For purposes of this Module,
select a coil rating of 120 volts.
6. Tabulate the contactor selection parameters determined in Steps 1 through 5.
7. Select a low voltage contactor from Westinghouse Catalog 25-000, pages 356 - 359
(Work Aid 1E, Handout 3).
8. 16-SAMSS-503 requires that only combination controllers be used for motors that are
rated 600 V and below, and 1 to 100 horsepower. As a result, contactors are supplied
by the manufacturer as an integral component of the combination controller. These
selection procedures provide for verifying the selection of contactors that are provided
with combination controllers.

Work Aid 1I: Applicable Procedures for Selecting a Fault Disconnect/Protective

Device
1. Collect the following data from the motor nameplate (if available):
• horsepower (hp)
• full-load amperes nameplate (FLA) -
• voltage (VM) -
• service factor (S.F.) - Note: Saudi Aramco specifies only 1.0 S.F. motors.
• kVA code letter -
2. Collect the following data, based on motor horsepower and voltage, from NEC Tables
430-150 and 430-151 (Handout 1):
• NEC full-load amperes (FLAN) -

• NEC locked-rotor amperes (LRAN) -
3. Collect the maximum symmetrical short circuit current available (SCA) from the
system one-line diagram:
• Short circuit current available (SCA) -
4. Calculate a required breaker interrupting rating 105 percent greater than the maximum
SCA: Notes: 1) Saudi Aramco design practices require that all electrical equipment
interrupting and withstand ratings be equal to 105 percent of SCA. 2) Magnetic-only
and MCP-interrupting ratings are part of the listed combination controller ratings.
• Breaker interrupting rating in amperes - Iint = 1.05 x SCA
5. If using MCP fault/disconnect protection, select the next standard size MCP (including
magnetic trip ranges) from Westinghouse Catalog 25-000 (Work Aid 1D, Handout 3),
pages 127 or 128, that equals or exceeds the voltage (VM), NEC full-load amperes
(FLAN) breaker interrupting rating (Iint), and locked rotor amperes (LRAN) from Steps
1, 2, and 4 above. Note: All Westinghouse MCP interrupting ratings are 65 kA. If
higher ratings are required, which is considered unlikely for refinery operations, an
MCP must be selected with a current limiter attachment that increases the rating to
100 kA.
6. If using a magnetic-only breaker, follow the same procedures as in Step 5. Note: This
Module limits selection to MCPs for motors less than or equal to 75 kW (100 hp).

7. If using an LVPCB controller, select the next standard size from Westinghouse SA-
11647 (Work Aid 1F, Handout 4), page 7, that equals or exceeds VM, 1.15 FLAN, and
Iint from Steps 1, 2, and 4 above. Note: SAES-P-114 (Work Aid 1A) requires LVPCBs
used as motor starters to have continuous current ratings 115 percent greater than
FLAN.
8. Select ground fault protection for motors above 30 hp.
a. If using MCP fault/disconnect protection, select a ground fault protection

device from pages 480 and 481 of Westinghouse Catalog 25-000 (Work Aid
1E,
Handout 3). Note: SAES-P-114 requires zero sequence, window-type CTs for
motor ground fault protection. SAES-P-114 also requires that the ground
fault protection device operate without auxiliary power. Therefore, this ground
fault device must be selected using flux transfer shunt trips.
b. If using LVPCB controllers, select the ground fault function (G) whenselecting
the breakers trip functions. Note: SAES-P-114 requires zero-sequence,
window-type CTs for motor ground fault protection.
9. As an alternative to selecting the individual fault/disconnect protective device, select

from the vendor’s list an enclosed combination motor starter (O/L relay, contactors,
fault/disconnect device, and enclosure). Therefore, if using this option, select a
combination motor starter from Westinghouse Catalog 25-000 (Work Aid 1D,
Handout 3), pages 406, 407, 415 and 416. The combination starter ratings must equal
or exceed VM, FLAN, and Iint from Steps 1, 2, and 4 above.

WORK AID 2: RESOURCES USED TO SIZE AC INDUCTION MOTOR CIRCUIT

CONDUCTORS
Work Aid 2A: SAES-P-114
1. Section 4.1 specifies that design and installation of wiring and cable systems shall be
in accordance with NFPA 70 (National Electric Code - NEC), as supplemented by this
Standard.
2. Section 4.2.1 specifies that wire and cable shall have copper conductors.
3. Section 4.2.2 specifies that low voltage wire and cable (600 V or 600/1000 V and
below) shall have a minimum rating of 750C.
4. Section 4.2.5 specifies that power conductors shall be stranded copper, except that
solid copper conductors 6 mm2 (No. 10 AWG) and smaller may be used in non-
industrial locations, and for specialty applications.
5. Section 4.2.10 specifies that for 600 V and below power conductors, the minimum size
permitted is 2.5 mm2 (No. 14 AWG).
6. Section 4.3.1 specifies that direct buried conduit shall be threaded, rigid steel, hot-dip
galvanized, and PVC-coated or type DB PVC conduit.
7. Section 4.3.2 specifies that conduit above ground in outdoor industrial facilities shall be
threaded, rigid steel, and be hot-dip galvanized.
8. Section 4.3.4 specifies that the minimum conduit size shall be 3/4-inch, except on
instrument panels, inside buildings, and on prefabricated skids, where the minimum
size conduit shall be 1/2-inch.
9. Section 5.1 specifies that the minimum burial depths for 600 V and below
underground installations shall be the following:
• Direct Buried cables - 600 mm (24 in.)

• Duct bank and direct buried rigid steel conduit - 460 mm (18 in.)
• PVC conduit, rigid steel conduit, or duct bank under roads, parking lots, and
other areas subject to vehicular traffic - 600 mm (24 in.)
10. Section 8.2.5 specifies that a derating factor of 15 percent shall be applied to power
cables that require fireproofing.

Work Aid 2B: SAES-P-100
1. Section 5.6.1(A) specifies that summation of voltage drops in main and feeder circuits
supplying motor control equipment located remotely from its supply switchgear shall
be 3 percent maximum at full load.
2. Section 5.6.1(A) specifies that summation of voltage drops in main and feeder circuits
supplying motor control equipment located in the same room as its supply switchgear
shall be 1 percent maximum at full load.
3. The maximum voltage drop in motor branch circuits shall not exceed 3 percent at full
load.
4. Section 6.2 specifies that the following criteria (Figure 87) shall be used to establish
equipment derating when specific requirements are not covered in an SAES or
SAMSS.
Location Ambient Temperature

Average Monthly Maximum
Normal Maximum Daily Peak
0 0
C C
Outdoors 45 50
Indoors - 40 50
Well-Ventilated Buildings
Indoors - 35 35
Air-Conditioned
Buildings Unmanned
Areas
30 30
Indoors -
Air-Conditioned
Buildings Manned Areas
Figure 87. SAES-P-100 Ambient Temperatures

Work Aid 2C: 1993 National Electric Code Handbook Article 430
For the content of Work Aid 2C, refer to Handout 1.

Work Aid 2D: Applicable Procedures for Sizing AC Induction Motor Branch Circuit
Conductors
Step 1. Determine the motor full-load amperes based on the values listed in NEC Tables
430-147 to 430-150 (Handout 1, pages 506-508).
• Motor FLA -
Step 2. Calculate the minimum branch circuit conductor ampacity at 125% of motor FLA
from Step 1.
• Conductor ampacity -
Step 3. Select an initial 750C or 900C conductor from NEC Table 310-16 (Handout 1, page
248) based on the ampacity from Step 2.
• Initial conductor selection -
Step 4. Apply any applicable derating factors as follows:
a. Temperature: See NEC Table 310-16 (Handout 1, page 248).
b. Fireproofing: 15% derating
• Conductor selected -
Step 5. Determine the conductor’s short circuit withstand capability.
a. Calculate the magnitude of the fault current (total asymmetrical) in accordance

with the following formula:
• Iasy = Isym x ko
• where: Isym - rms symmetrical fault current
Note: Isym is assumed as a “given quantity” for purposes of the Work Aid.
k0 = correction factor accounting for the dc component of current.

= 1.6 for MCCBs
= 1.3 for LVPCBs

b. Select a duration time (t) from Figure 88 or alternatively calculate the duration
(t) of the short circuit in accordance with the following formula:
• t = .0297 log10 [(T2 + 234)/T1 + 234)] x (A/Iasy)2
• where: t = short circuit duration in seconds
T1 = initial conductor temperature in degrees Celsius (0C)

= 750C or 900C for NEC thermoplastic (PVC) conductors
T2 = final conductor temperature in degrees Celsius (0C)

= 1500C for NEC thermoplastic (PVC) conductors
A = conductor cross-sectional area in circular mils (cmils)

Note: See Table 8 of the NEC Handbook (Handout 1, page
919).
Iasy = maximum asymmetrical short circuit current in amperes

calculated in Step 5a.
c. Compare the short circuit duration (t) selected or calculated in Step 5b to the
estimated protective device clearing times from below. If t is less than the
protective device’s clearing time, increase the conductor size to the next
standard available size and repeat Steps 4 and 5 until t is greater than the
protective device’s clearing time.
(1) Molded Case Circuit Breakers (MCCBs) and MCPs: 1.1 cycles (18 msec)
for less than 100 ampere frame (AF), and 1.5 cycles (25 msec) for 225 AF
and larger in the MCCB’s or MCP’s instantaneous range (approximately
five times ampere trip for the MCCB).
(2) Low Voltage Power Circuit Breakers (LVPCBs): 3 cycles (0.05 sec) for
instantaneous ranges.

Figure 88. ICEA Cable Damage Curves

Step 6. Calculate the voltage drop.
a. Determine the load power factor angle θ = cos-1 p.f.
b. Calculate the load reactive factor (sin θ). sin θ = sin (cos-1 p.f.)
c. Determine branch circuit impedance (ZΩ) per 1000 feet from NEC Table 9
(Handout 1, page 920).
d. Calculate the branch circuit impedance.
ZΩ = ((R + jX) Ω per 1000 ft) (number of feet)
e. Calculate VD line-to-neutral (one-way).
VD = I(R cos θ + X sin θ)
f. Calculate VD line-to-line
VD = 3 VD (3φ system)
VD = 2VD (1φ system)
g. Calculate the load voltage (VL)
VL = VS - VD
h. Calculate VD as a percentage (VD%).
VD% = 100[(VS - VL)/Vs]
i. If VD% exceeds 3 percent, increase the conductor to the next standard size and
repeat Steps 6c through 6i.
Step 7. Determine the conduit size.
a. If using an inverse-time MCCB or an LVPCB for short circuit protection, select

the next standard size breaker (NEC Article 240-6) rating not to exceed 250
percent of motor FLA. Note: Skip to Step 7c.

b. If using an instantaneous trip only MCCB or an MCP, for short circuit

protection, select a rating or setting for the device not to exceed 700 percent of
motor FLA. Note: Skip to Step 7d.
c. Select an equipment grounding conductor (EGC) from NEC Table 250-95

(Handout 1, page 199) based on the rating of the inverse-time MCCB or
LVPCB selected in Step 7a.
• EGC selected -
Note: Skip to Step 7E.
d. If using an instantaneous trip only MCCB or an MCP, for short circuit

protection, select an EGC from NEC Table 250-95 (Handout 1, page 199)
based on an ampacity rating not to exceed 115 percent of motor FLA.
• 1.15 X motor FLA -
• EGC selected -
e. Select a conduit from NEC Tables 3A, 3B, or 3C (Handout 1, pages 913-915) based
on the size and type of the branch circuit conductors selected in Step 4 and the
EGC conductor selected in Step 7d.
• Conduit trade size selected -

Work Aid 2E: Motor Branch Circuit Design Flow Chart
Figure 89. Motor Branch Circuit Design Flow Chart

Work Aid 2F: Applicable Procedures for Sizing AC Induction Motor Feeder
Conductors
Step 1. Determine each of the motor’s full-load amperes based on the values listed in NEC
Tables 430-147 to 430-150 (Handout 1, pages 506-508).
• Motor 1 FLA -
• Motor 2 FLA -
• Motor XX FLA -
Step 2. Calculate the minimum feeder conductor ampacity as follows:
• FLAM1 + FLAM2 +...+FLAMXX + .25 X FLA (largest motor)
• Conductor ampacity -
Step 3 through Step 6: See Steps 3 through 6 of Work Aid 2D, this Module.
Step 7. Determine the conduit size.
a. Select an MCCB or LVPCB protective device rating based on the sum of the
ampacity rating of the largest motor branch circuit device plus the full-load
amperes of all of the other motors.
• Protective device rating -
b. Select an equipment grounding conductor (EGC) based on the rating of the

protective device selected in Step 7a.
• EGC selected -
c. Select a conduit from NEC Tables 3A, 3B, or 3C based on the size and the type
of feeder circuit phase conductor selected in Step 3 and the size of the EGC
selected in Step 7b.
• Conduit trade size selected -

Work Aid 2G: Motor Feeder Circuit Design Flow Chart
Figure 90. Motor Feeder Circuit Design Flow Chart

GLOSSARY
air magnetic breaker A type of medium voltage circuit breaker that has its electrical
contacts in air. An electromagnet built into the arc chutes aids
in extinguishing the arc.
ANSI American National Standards Institute
asymmetrical (current) The combination of the symmetrical component and the direct-
current component of the current equals the asymmetrical
current.
circuit breaker control A rotary power switch that is designed for heavyduty control
switch systems.
combination starter A complete motor starter that consists of a disconnect device, a

magnetic contactor, and protective devices for short circuit and
overload, and all other devices that are assembled in a single
enclosure.
contactor A magnetic device that has sufficient capability to connect and

disconnect the electric circuit of a motor under normal and
overload conditions.
control circuit The circuit that carries the electric signals directing the
performance of the controller, but does not carry the main
power circuit current.
control relay A component that is used in a motor starter’s control circuit to

interface between a pilot device and the circuit that the pilot
device controls.
control power A transformer that is used to draw control power from the main
transformer (CPT) power circuit of a motor starter.
duty (rotating machinery) A variation of load with time, which may or maynot be
repeated, and in which the cycle time is too short for thermal
equilibrium to be attained.
full-voltage starter A type of motor starter that applies full voltage to the motor
terminals during the starting period.
horsepower (shaft) (hp) The ANSI/IEEE mechanical output (shaft) rating of a motor is

measured in hp, where one (1) hp equals 746 watts. See

kilowatt (shaft).
induction motor An alternating-current motor in which a primary winding on

one member (usually the stator) is connected to the power
source, and in which a polyphase secondary winding or a
squirrel-cage secondary winding on the other member (usually
the rotor) carries induced current.
IEC International Electrotechnical Commission
IEEE Institute of Electrical and Electronics Engineers
interposing relay Special relays that are used in the control circuits of larger size
contactors to interface (or interpose) between the relatively high
coil current required by the large size contactors, and the
pushbuttons or control contacts used to switch-off or break their
current.
jogging The quickly repeated closure of the circuit to start a motor from
rest for the purpose of accomplishing small movements of the
driven machine is called jogging.
kilowatt (shaft) (kw) The IEC mechanical output (shaft) rating of a motor is
measured in kW. See horsepower (hp).
locked-rotor (rotating The condition that exists when the circuits of a motor are
machinery) energized, but the rotor is not turning, is called locked-rotor.
locked-rotor current The steady-state current that is measured on the line, with the
rotor locked and with rated voltage (and rated frequency in the
case of alternating-current motors), applied to the motor.
locked-rotor indicating Code letters that are marked on a motor nameplate to show
code letter motor kVA per hp under locked-rotor conditions.
low voltage Voltage levels that are below 1000 volts and are often called
utilization level outages.
manual starter A simple type of motor starter that provides full-voltage, on-off
type operation for small single-phase and three-phase motors.

motor circuit protector A magnetic-only molded case circuit breaker that is used in low
(MCP) voltage combination starters. An MCP has only instantaneous
functions to protect the motor, starter, and branch circuit from
short circuit and ground fault currents.
NEC National Electric Code
overload relay (O/L) A device that is used to sense an overload on a motor circuit.
The most common type of O/L relay uses a heater that heats a
bimetallic strip that operates a set of contacts.
pilot device Control and indicating devices that are used in motor control
circuits. These devices include indicating lights, switches, and
pushbuttons.
reduced-voltage starter A type of motor starter that applies less than full-voltage to the
motor terminals during the starting period.
relay An electric device that is designed to interpret input conditions

in a prescribed manner, and, after specified conditions are met,
to respond to cause contact operation or similar abrupt change
in associated electric control circuits.
replica temperature relay A thermal relay, where the internal temperature rise is
proportional to that of the protected apparatus or conductor,
over a range of values and durations of overloads.
residual (current) The sum of the three-phase currents measured in a three-phase

circuit. The current that flows in the neutral return circuit of
three wye-connected current transformers is called residual
current.
reversing starter A type of motor starter that provides for reversing the direction
of rotation of the motor.
rotor (rotating The rotating member of a machine with shaft is called the rotor.
machinery)
SAES Saudi Aramco Engineering Standard
SAMSS Saudi Aramco Material Specification Standard
service factor (S.F.) A multiplier that, when applied to the rated power, indicates a

permissible power loading that may be carried under the

conditions specified for the service factor.
single-phasing (motor) An abnormal operation of a polyphase machine when its supply

is effectively single-phase.
solid-state contactor A contactor whose function is performed by semiconducting

devices.
starter (motor) An electric controller that accelerates a motor from rest to

normal speed, and that stops the motor.
starting current(rotating The current drawn by the motor during the starting period is
machinery) called starting current and it is a function of speed or slip.
stator (rotating The portion of a machine that includes and supports the
machinery) stationary active parts. The stator includes the stationary
portions of the magnetic circuit and the associated winding and
leads. It may, depending on the design, include a frame or
shell, winding supports, ventilation circuits, coolers,and
temperature detectors. A base, if provided, is not ordinarily
considered to be part of the stator.
symmetrical (current) A periodic alternating current where the waveshapes are one-
half a period apart, equal, and have opposite signs.
temperature rise test the A test that is undertaken to determine temperature rise above
(rotating machinery) ambient of one or more parts of a machine under specified
operating conditions. The specified conditions may refer to
current, load, etc.
three-wire control The most common type of motor control used to start and stop a
motor is called three-wire control.
time-current (T/C) The correlated values of time and current that designate the
characteristics performance of all or a stated portion of the functions of a
protective device. The time-current (T/C) characteristics of a
protective device are usually shown as a curve.
two-wire control The type of motor control that automatically starts and stops a
motor depending on the set points of a pilot device.
zero sequence current Three balanced current phasors that are equal in magnitude and
components with zero displacement from each other are called zero

sequence components. Zero sequence currents are often called

ground fault currents.

EEX10303 Designing LV Motor Circuit

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Engineering Encyclopedia

Saudi Aramco DeskTop Standards

Designing Low Voltage

Chapter : Electrical For additional information on this subject, contact

MOTOR STARTER CONTROL CIRCUITS ................................................................ 1

Saudi Aramco DeskTop Standards

Saudi Aramco DeskTop Standards

SIZING MOTOR CIRCUIT CONDUCTORS........................................................... 107

Saudi Aramco DeskTop Standards

WORK AID 2: RESOURCES USED TO SIZE AC INDUCTION MOTOR

Saudi Aramco DeskTop Standards

MOTOR STARTER CONTROL CIRCUITS

• Reduced voltage wye-delta starter

• Circuit breaker starter

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Control Circuit Components

Figure 1. Typical Motor Starter Control Circuit Schematic

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Figure 2. Normally Open Pushbutton

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Figure 3. Normally Closed Pushbutton

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Figure 4. Types of Contact Assembly Blocks

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In addition to other considerations, pushbuttons are designed and manufactured to meet

Figure5. NEMATypeDesignation (ReferenceNEMAStd.No.250-1991)

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Position Versions - A position-type selector switch (Figure 6) is similar to a pushbutton in

Figure 6. Position-Type Selector Switch

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Figure 7. Schematic Diagram of Selector-Type Position Switch

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Figure 8. Typical Circuit Breaker Control Switch

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Figure 9. Lamp-Base Styles

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Transformer-Type - The transformer-type indicating light is essentially designed for use

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Figure 11. Push-To-Test Indicating Light

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Figure 12. Typical Control Relays

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Control Power Transformers (CPT)

Figure 13. Typical Voltage Ratings for Control Power Transformers

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Figure 15. Types of Controllers

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Figure 16. Typical Operating Characteristics for AC Coils

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Figure 17. Typical Operating Characteristics for DC Coils

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Circuit Breaker or MCP

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Overload (O/L) Relay

Figure 18. Example of Overload Relay Ratings

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Control Logic Description: Manual Starter

Figure 19. Fractional Horsepower Toggle Switch Starter

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Figure 20. Integral Horsepower Pushbutton Starter (Manual)

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