MOTOR CONTROL CENTRE (MCC) MCCB DESIGN RATING

I would like to present calculation on the sizing of the breakers.

To size up the incoming breakers for the Motor Control Centers (MCC), “Writing Manual -
Automation and Power Distribution, by Klocker Moeller” introduces the formulas for Full Load
Current calculations as follows:

Where

In addition, “Practical Aspects of Electric Motor Controls, by Telemecanique” states that the
current drawn by a three-phase motor starter at start up is several times more than its rated
operating current.

Starter Starting Current Starting Time

DOL
S/D
A/T

Table 1: Summary of Characteristics of Different Motor Starters

Based on the calculation of starting current for the motor starters, we are able to size up the
breaker according to the operating curve for the MCCB and MCB. It emphasizes that the
sufficient time for the motor shall be started up without tripping the breaker. The breaker will
only tripped whenever the motor tripping occurs, but not because of motor starting operation.
Kindly refer to the operating curve enclosed accordingly to the various breaker types.

The breaker tripping time should be theoretically higher than the normal starting times for the
motor starter due to the requirement stated.

Normal Starting Time (DOL or S/D or A/T) < Breaker Tripping Time

CASE 1
MCC Panel “MCC-TE-MF-22-03E”

INCOMING: 1 x 80A 3P MCCB

OUTGOING 1: A/T STARTING WITH 1 UNIT OF 50A 3P MCCB AS INCOMING,
CONNECTED TO A 11KW MOTOR
OUTGOING 2: S/D STARTING WITH 1 UNIT OF 20A 3P MCCB AS INCOMING,
CONNECTED TO A 5.5KW MOTOR
OUTGOING 3: DOL STARTING WITH 1 UNIT OF 6A 3P MCB AS INCOMING,
CONNECTED TO A 0.55KW MOTOR

A) TO ENSURE THAT INCOMING BREAKER DO NOT ABRUPTLY TRIP DURING

MOTOR STARTING
B) TO ENSURE THAT OUTGOING BREAKER DO NOT ABRUPTLY TRIP DURING
MOTOR STARTING

ASSUMPTION TAKEN:

POWER FACTOR,
MOTOR EFFICIENCY,
VOLTAGE,
INCOMING CALCULATION

CONSIDERING 2 DUTY 1 STANBY MOTOR OPERATION, OUTGOING 1 AND 2 SHALL

START SIMULTANEOUSLY AND OUTGOING 3 SHALL REMAIN AT STANDBY
MODE.

FULL LOAD CURRENT (FLC) FOR OUTGOING 1:

Starting Current

FULL LOAD CURRENT (FLC) FOR OUTGOING 2:

Starting Current

Breaker Used = 80A 3P MCCB

BASED ON TABLE A, BREAKER TRIPPING TIME IS 2.2 minutes,

Normal A/T Starting Time = 12 seconds

Normal S/D Starting Time = 7 seconds

Normal Starter Starting Time (DOL or S/D or A/T) < Breaker Tripping Time
(7+12) seconds < 1.5 minutes (90 seconds)

THREFORE, 80A TPN MCCB CAN BE USED AS AN INCOMING BREAKER FOR MCC-
TE-MF-22-03E.
OUTGOING 1 CALCULATION

FULL LOAD CURRENT (FLC) FOR OUTGOING 1:

Starting Current

Breaker Used = 50A 3P MCCB

BASED ON TABLE A, BREAKER TRIPPING TIME IS 1.5 minutes,

Normal A/T Starting Time = 12 seconds,

Normal Starter Starting Time (DOL or S/D or A/T) < Breaker Tripping Time
12seconds < 1.5 minutes (90 seconds)

THREFORE, 50A TPN MCCB CAN BE USED FOR INCOMING BREAKER FOR
OUTGOING 1.
OUTGOING 2 CALCULATION

FULL LOAD CURRENT (FLC) FOR OUTGOING 2:

Starting Current

Breaker Used = 20A 3P MCCB

BASED ON TABLE B, BREAKER TRIPPING TIME IS 1.5 minutes,

Normal S/D Starting Time = 7 seconds,

Normal Starter Starting Time (DOL or S/D or A/T) < Breaker Tripping Time
7seconds < 1.5 minutes (90 seconds)

THREFORE, 20A 3P MCCB CAN BE USED FOR INCOMING BREAKER FOR OUTGOING
2.
OUTGOING 3 CALCULATION

FULL LOAD CURRENT (FLC) FOR OUTGOING 3:

Starting Current

Breaker Used = 6A 3P MCB

BASED ON TABLE C, BREAKER TRIPPING TIME IS 4 minutes,

Normal DOL Starting Time = 3 seconds,

Normal Starter Starting Time (DOL or S/D or A/T) < Breaker Tripping Time
3 seconds < 4 minutes (90 seconds)

THREFORE, 20A 3P MCCB CAN BE USED FOR INCOMING BREAKER FOR OUTGOING
3.
TABLE A (50A, 80A 3P MCCB TRIP CURVE)

TABLE B (20A 3P MCCB TRIP CURVE)

TABLE C (32A 3P MCCB TRIP CURVE)

TABLE D (MCB TRIP CURVE)

MOTOR CONTROL CENTRE (MCC) CONTACTOR & THERMAL OVERLOAD &v
AUTO TRANSFORMER RELAY DESIGN RATING

All contactors and thermal overload relays must be in accordance to utilization category AC-3

DOL Starting:

The contactor rating shall be selected by referring to the motor Full Load Current (FLC) of the
connected motor.

The thermal overload protection range shall be the selected by using the Full Load Current
(FLC) as the mid range reference point with a minimum and maximum tolerance of 20%.

Star Delta Starting:

There will be 3 (SC-DC-LC) contactor selections due to star connection and delta connection in
this type of motor starter.

The star contactor (SC) rating shall be selected by knowing that star circuit will draw 1/3 of the
starting current. Therefore, star contactor shall be selector base on Isc.

The delta contactor (DC) rating shall be selected by knowing that each phase
of the delta circuit, Idc will be:
Therefore, the delta contactor shall be selected based on Idc.

The line contactor (LC) rating shall be selected same as delta contactor because DC Contactor
and LC Contactor are energize to run together at all times.

The thermal overload protection range shall be the selected by the value of Idc as the mid range
reference point with a minimum and maximum tolerance of 20%.

AutoTransformer Starting:

There will be 3 (SC-TC-LC) contactor selections due to the autotransformer connection in this
type of motor starter.

We shall refer autotransformer with voltage tappings of 50%-65%-80%.

The LC contactor rating shall be selected by referring to the Full Load Current (FLC) of the
connected motor.

The SC and TC contactor shall be selected based on transformer primary current. Elaboration is
as stated below:

Itransformer = a2 x IFLC, a = transformer % tapping

When autotransformer tapping is at 50%, Itransformer = 0.25 IFLC, SC contactor rating shall be based
on 0.25 IFLC.

When autotransformer tapping is at 80%, Itransformer = 0.64 IFLC, TC contactor rating shall be based
on 0.64 IFLC.

The thermal overload protection range shall be the selected by using the Full Load Current
(FLC) as the mid range reference point with a minimum and maximum tolerance of 20%.