Motor starting problem and high motor inrush currents

http://electrical- engineering- portal.com/motor- starting- problem- and- high- motor- inrush- currents January 15, 2013

Elect ric mot or protection device depends on

the accurate and correct selection of overload(s),
fuses and/or circuit breakers. Over the years the
protective devices have been selected according
to the applicable code requirements with only
minimal nuisance tripping. However, in recent
years, the problem of nuisance tripping due to
the high mot or inrush current s that occur during
motor starting has gained increased attention.

In order to avoid the problem of nuisance

tripping, application engineers have been forced
to either set the HMCP magnetic circuit breaker
above code requirements or take a step
backward and exchange the HMCP circuit breaker
for an inverse time circuit breaker. Both scenarios
Allen Bradley Motor Controller/Starter Bucket -
have the disadvantage of sacrificing the close
With HMCP Cutler-Hammer 30 Amp Circuit
coordination protection for which HMCPs were Breaker
initially designed.

The National Electric Code (NEC) was changed

slightly in 1996 to address this problem. The problem stems from the fact that the NEC allows
certain settings for HMCPs (currently 800% of full load current, 1100% for design E motors) based
on the motor’s locked rotor current (LRC), which is generally 600% to 700% of full load current
(FLC). However, with high efficiency motors the inrush current may exceed the 800% of FLC.

Also, the application voltage may be over the nominal by 3 to 5%.

These factors will cause the initial inrush current to be much higher than usual. Additionally, one
other phenomenon that will exacerbate the situation is that the initial peak inrush current will not
be symmetrical.

Top

Why is Inrush Current So Much Higher Than LRC?

The basic answer is… LRC is not the only component of inrush current. This raises the question:
“What else is there?”

LRC is a steady state current. That is, it remains constant so long as the rotor is not moving.
Motors, however, are highly inductive loads. Like all inductive loads they generate an initial
transient (short lived) response which causes the load to draw more current.

The steady state LRC is symmetrical when voltage is near zero. The initial transient response
raises the LRC curve so that it is no longer symmetrical – thus giving it the name “asymmetrical
offset”. This asymmetrical offset usually lasts only a few cycles as the current settles to a normal
steady state LRC, which dies off as the motor begins to rotate (refer to Figure 1).

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The

Figure 1: Current wavef orm showing an asymmetrical inrush

asymmetrical offset is dependent mainly upon at which point on the voltage wave the circuit is
energized. If the circuit is energized at a voltage maximum, there is no asymmetrical offset and the
inrush current is essentially the LRC for that current phase. However, if the circuit is energized
when the voltage is zero the initial inrush current is made completely asymmetrical, that is, shifted
from the nominal current axis (refer to Figure 2).

This makes the inrush current greater than the LRC for that current phase.

Also, in a three phase system, the odds of one of the phases being at or near voltage zero when
starting a motor is very high. This explains the source of nuisance tripping. Considering the actual
asymmetrical inrush current could be, according to NEMA manufacturers, as much as two times
the LRC. A HMCP circuit breaker (that is set based on the LRC) and is used with a high efficiency
motor will experience nuisance tripping during energizing.

Thus, the inrush could be 18 times the FLC – much higher than the 13 times FLC that the
HMCP circuit breaker may be set to by the NEC.

So

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So
What
Do I
Do

Figure 2: First cycle current can dif f er greatly depending on what point on the voltage wave the
circuit is energized

About It?
If your motor control center equipment has already been installed, one may have few options:

Choose a HMCP circuit breaker with a higher instantaneous trip range.

Substitute a thermal magnetic circuit breaker with a higher instantaneous trip range.

If you are still in the planning stages, making a few additional considerations now can save
you a lot of headaches down the road.

Get a complete set of specifications from the motor manufacturer and be sure to request
data on the actual maximum inrush current along with the FLC and/or LRC ratio data.
Specify motors with inrush to FLC ratios that would prevent you from violating the NEC.
Make certain the motor is built to NEMA standards.
Do not exceed the nominal voltage by more than 2 or 3%.
Encourage the National Fire Protection Association (NFPA) to further address this issue in
future editions of the NEC.

SOURCE: Rockwell Automation | Allen-Bredley – High Efficiency Motor Protection

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